Milwaukee Corded Band Saw: Model Identification, Setup, and Common Repairs
You own a Milwaukee corded band saw and you need to identify the model, set it up, or repair it. Milwaukee corded band saws are portable band saws powered by a corded electric motor. You need to know the models, specifications, and common repairs.
Milwaukee corded band saws are portable band saws powered by a corded electric motor. They are designed for cutting metal pipe, conduit, unistrut, and bar stock. Milwaukee offers several corded models, including the 6232-20, 6238-20, and the older 6230-20.
Model Identification
Common Milwaukee Corded Models
| Model | Type | Blade Length | Cut Capacity | Speed | Notes |
|---|---|---|---|---|---|
| 6232-20 | Deep cut, single speed | 44-7/8 inches | 4-3/4 x 4-3/4 inches | 200 SFPM | Popular |
| 6238-20 | Deep cut, variable speed | 44-7/8 inches | 4-3/4 x 4-3/4 inches | 120-200 SFPM | Variable speed |
| 6230-20 | Deep cut, single speed (older) | 44-7/8 inches | 4-3/4 x 4-3/4 inches | 200 SFPM | Older model |
| 6236-20 | Compact (older) | 32-7/8 inches (verify) | 2-1/2 x 2-1/2 inches | 200 SFPM | Less common |
How to Identify Your Model
- Find the model number on the label on the motor housing.
- If the label is missing, check the saw for stamped numbers.
- Check the blade length to identify the saw type (44-7/8 for deep cut, 32-7/8 for compact).
- Contact Milwaukee customer service with any identifying numbers.
Specifications
Deep Cut Models (6232-20, 6238-20)
| Specification | 6232-20 | 6238-20 |
|---|---|---|
| Type | Deep cut, single speed | Deep cut, variable speed |
| Motor | 6 amp, 120V | 6 amp, 120V |
| Speed | 200 SFPM | 120 to 200 SFPM |
| Cut capacity | 4-3/4 x 4-3/4 inches | 4-3/4 x 4-3/4 inches |
| Blade length | 44-7/8 inches | 44-7/8 inches |
| Weight | ~14 pounds | ~14 pounds |
| Power | 120V corded | 120V corded |
Setup
1. Install the Blade
- Open the blade guard.
- Release blade tension.
- Install the blade with teeth pointing down (toward the shoe).
- Apply tension.
- Check tracking.
- Close the blade guard.
2. Adjust the Shoe
The shoe (foot) can be adjusted for different cut depths. Loosen the shoe locking lever, adjust the shoe position, and tighten the lever.
3. Set the Speed (6238-20 Only)
The 6238-20 has a variable speed dial. Set the speed based on the material:
- Mild steel: 120 to 200 SFPM
- Stainless steel: 120 SFPM
- Aluminum: 200 SFPM
4. Make the Cut
- Plug in the saw.
- Position the saw on the workpiece.
- Squeeze the trigger.
- Let the saw reach full speed.
- Feed the saw into the material with steady pressure.
- Do not force the cut.
Common Repairs
1. Blade Replacement
When: When cuts become rough or the blade breaks. How: Open the guard, release tension, remove the old blade, install the new blade, apply tension, check tracking. Cost: 15 to 30 dollars.
2. Switch Replacement
When: The switch does not turn the saw on or off reliably. How: Disconnect power, remove the switch cover, disconnect the switch wires, install the new switch, reconnect the wires, replace the cover. Cost: 15 to 25 dollars.
3. Power Cord Replacement
When: The cord is cut, frayed, or damaged. How: Disconnect power, remove the cord strain relief, disconnect the cord from the switch, install the new cord, reconnect, replace the strain relief. Cost: 15 to 25 dollars.
4. Blade Guide Replacement
When: The blade guides are worn and the blade wanders. How: Remove the guide assembly, install the new guides, adjust the guide clearance. Cost: 20 to 40 dollars.
5. Motor Brush Replacement
When: The motor runs intermittently or loses power. How: Remove the brush caps, remove the old brushes, install the new brushes, replace the caps. Cost: 10 to 20 dollars per pair.
6. Bearing Replacement
When: The saw makes grinding or rumbling noise. How: Disassemble the saw, remove the old bearings, install the new bearings, reassemble. Cost: 15 to 30 dollars per bearing.
Maintenance
Daily: Clean chips from the blade guard and shoe. Check the blade for wear. Weekly: Clean the blade guide area. Check the power cord for damage. Monthly: Check all screws and bolts for tightness. Lubricate the shoe adjustment mechanism. Annually: Replace the motor brushes. Check the bearings. Inspect the switch and cord.
FAQ
What is the difference between the Milwaukee 6232-20 and 6238-20?
The 6232-20 is a single speed saw (200 SFPM). The 6238-20 is a variable speed saw (120 to 200 SFPM). Both are deep cut saws with 4-3/4 x 4-3/4 inch cut capacity using 44-7/8 inch blades.
What blade does the Milwaukee corded band saw use?
Deep cut models (6232-20, 6238-20) use 44-7/8 inch blades. Compact models use 32-7/8 inch blades (verify by model).
Where can I find parts for my Milwaukee corded band saw?
Milwaukee Tool service centers, eReplacementParts, Amazon, and eBay. Common parts like blades, switches, cords, and brushes are widely available.
References
- Milwaukee Tool. “6232-20 Owner’s Manual.” Milwaukee Tool.
- Milwaukee Tool. “6238-20 Owner’s Manual.” Milwaukee Tool.
- eReplacementParts. “Milwaukee 6232-20 Parts Diagram.” eReplacementParts.com.
- Pro Tool Reviews. “Milwaukee Corded Band Saw Review.” ProToolReviews.com.
- Tool Box Buzz. “Milwaukee Portable Band Saw Guide.” ToolBoxBuzz.com.
