Bosch 3540 User Manual

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“READ ALL INSTRUCTIONS” — Failure to follow the SAFETY RULES identified by BULLET (•) symbol listed


BELOW and other safety precautions, may result in serious personal injury.



General Safety Rules

for Bench Top Tools

Work Area

Keep work area clean and well lit. Cluttered benches and dark areas invite accidents.

Do not operate power tools in explosive atmospheres, such as in the presence of flammable liquids, gases or dust. Power tools create sparks which may ignite the dust or fumes.

Keep bystanders, children and visitors away while operating a power tool. Distractions can cause you to lose control.

Store idle tools out of reach of children and other untrained persons. Tools are dangerous in the hands of untrained users.

Do not leave tool running unattended, turn power off.

Do not leave tool until it comes to a complete stop.

maKe woRKShop chilDpRoof with padlock, master switches, or by removing starter keys.

Electrical Safety

Before plugging in the tool, be certain the outlet voltage supplied is compatible with the voltage marked on the nameplate within 10%. An outlet voltage incompatible with that specified on the nameplate can result in serious hazards and damage to the tool.

avoid body contact with grounded surfaces such as pipes, radiators, ranges and refrigerators. There is an increased risk of electric shock if your body is grounded.

Do not expose power tools to rain or wet conditions.

Water entering a power tool will increase the risk of electric shock.

Do not abuse the cord. Never use the cord to carry the tools or pull the plug from an outlet. Keep cord away from heat, oil, sharp edges or moving parts. Replace damaged cords immediately. Damaged cords increase the risk of electric shock.

only use an outdoor extension cord marked “w-a”or “w”.These cords are rated for outdoor use and reduce the risk of electric shock.

Personal Safety

Stay alert, watch what you are doing and use common sense when operating a power tool. A moment of inattention or use of drugs, alcohol or medication while operating power tools can be dangerous.

Dress properly. Do not wear loose clothing or jewelry. contain long hair. Keep your hair, clothing and gloves away from moving parts. loose clothes, jewelry or long hair can be caught in moving parts.

Roll long sleeves above elbows. Rubber gloves and nonskid footwear are recommended when working outdoors.

avoid accidental starting. Be sure switch is “off” before plugging in. Carrying tools with your finger on the switch or plugging in tools that have the switch “ON” invites accidents.

Remove adjusting keys or wrenches before turning the tool “oN”. A wrench or a key that is left attached to a rotating part of the tool will be thrown.

Do not overreach, keep proper footing and balance at all times. Proper footing and balance enables better control of the tool in unexpected situations.

Do not stand on tool or its stand. Serious injury may occur if the tool is tipped or if the cutting tool is accidentally contacted. Do not store materials on or near the tool such that it is necessary to stand on the tool or its stand to reach them.

Use safety equipment. always wear safety goggles.

Dust mask, safety shoes, hard hat or hearing protection must be used for appropriate conditions. Everyday eyeglasses only have impact resistant lenses. They are NOT safety glasses

“SaVe TheSe iNSTRUcTioNS”


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“READ ALL INSTRUCTIONS” — Failure to follow the SAFETY RULES identified by BULLET (•) symbol listed


BELOW and other safety precautions, may result in serious personal injury.

Tool Use and Care

Use clamps or other practical way to secure and support the workpiece to a stable platform. Holding the work by hand or against your body is unstable. It allows for work to shift, causes binding of the tool and loss of control.

Do not force tool. Use the correct tool for your application. The correct tool will do the job better and safer at the rate for which it is designed. Do not use the tool for purpose not intended.

Do not use tool if switch does not turn it “oN” or “off”. Any tool that cannot be controlled with the switch is dangerous.

Disconnect the plug from the power source before making any adjustments or changing accessories.

Such preventive safety measures reduce the risk of starting the tool accidentally.

Keep cutting tools sharp and clean. Properly maintained tools, with sharp cutting edges, are less likely to bind and easier to control. When mounting saw blades be certain that the arrow on the blade matches the direction of the arrow marked on the tool and that the teeth are also pointing in the same direction.

inspect guards before using a tool. Keep guards in place. check moving parts for binding or any other condition that may affect the normal operation or safety features of the tool. if damaged, have tool serviced before using the tool. Many accidents are caused by poorly maintained tools.

Do not alter or misuse tool. Any alteration or modification is a misuse and may result in serious personal injury.

The use of any other accessories not specified in this manual may create a hazard. Accessories that may be suitable for one type of tool, may become hazardous when used on an inappropriate tool.


Tool service must be performed only by qualified repair personnel. Service or maintenance performed by unqualified personnel may result in misplacing internal wires and components which could cause serious hazard.

when servicing a tool, use only identical replacement parts. follow instructions in the maintenance section of this manual. Use of unauthorized parts or failure to follow Maintenance Instructions may create a hazard.

Safety Rules for

Tile Saws

To reduce the risk of electrocution, keep all connections dry and off the ground. Do not touch plug with wet hands.

To reduce the risk of electric shock, plug tile saw into Ground fault circuit interrupter (Gfci) protected outlet only. if a Gfci protected outlet is not available, use a portable receptacle with built-inGfci protection.

Disconnect saw from power source before making adjustments, servicing, cleaning, or changing blade.

Replace damaged tile blades before operating.

Use tool only with smooth edge tile blades free of openings and grooves.

after turning saw off, wait for blade to stop before removing cutoff pieces or changing settings.

Use top guard for every operation for which it can be used.

Do not reach in back of the saw blade with either hand to hold down or support the workpiece, remove scraps, or for any other reason. The proximity of the spinning tile blade to your hand may not be obvious and you may be seriously injured.

always disconnect the power cord from the power source before making any adjustments or attaching any accessories. You may unintentionally start the saw, leading to serious personal injury.

Do not use the saw until the table is clear of all tools, scraps, etc., except the workpiece and related feed or supported devices for the operation planned. Small debris or loose pieces of tile or other objects that contact the revolving blade can be thrown with high speed at the operator.

empty water from tile saw base before transporting.

Water left in base can splash into electrical components.

“SaVe TheSe iNSTRUcTioNS”


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“READ ALL INSTRUCTIONS” — Failure to follow the SAFETY RULES identified by BULLET (•) symbol listed


BELOW and other safety precautions, may result in serious personal injury.



cut only one workpiece at a time. Multiple workpieces cannot be adequately clamped or braced and may bind on the blade or shift during cutting.

Be certain the tile saw is mounted or placed on a level, firm work surface before using. A level and firm work surface reduces the risk of the tile saw becoming unstable.

This tool is not equipped with provisions for attaching an auxiliary fence. Insure that the work piece is supported by the fence before cutting.

Do not use another person as a substitute for a table extension or as additional support. Unstable support for the workpiece can cause the blade to bind or the workpiece to shift during the cutting operation pulling you and the helper into the spinning wheel.

The cutoff piece must not be jammed against or pressured by any other means against the spinning tile blade. If confined, i.e. using length stops, it could get wedged against the blade and thrown toward you.

let the blade reach full speed before contacting the workpiece. This will help avoid thrown workpieces.

if the workpiece or blade becomes jammed or bogged down, turn tile saw “off” by releasing switch. wait for all moving parts to stop and unplug the tile saw, then work to free the jammed material.

Continued sawing with jammed workpiece could cause loss of control or damage to tile saw.

Some dust created by power sanding, ! WARNING sawing, grinding, drilling, and other

construction activities contains chemicals known to cause cancer, birth defects or other reproductive harm. Some examples of these chemicals are:

Lead from lead-basedpaints,

Crystalline silica from bricks and cement and other masonry products, and

Arsenic and chromium from chemically treated lumber.

Your risk from these exposures varies, depending on how often you do this type of work. To reduce your exposure to these chemicals: work in a well ventilated area, and work with approved safety equipment, such as those dust masks that are specially designed to filter out microscopic particles.

There are additional safety instructions for particular operations of the saw in the operating section. Read the rest of the manual for safe operation.


Use the tile saw in a well lit area and on a level surface, clean and smooth enough to reduce the risk of trips and falls. Use it where neither the operator nor the casual observer is forced to stand in line with the blade.

To avoid the possibility of the appliance plug or receptacle getting wet, position tile saw to one side of a wall mounted receptacle to prevent water from dripping onto the receptacle or plug. The user should arrange a “drip loop” in the cord connecting the saw to a receptacle. The “drip loop” is that part of the cord below the level of the receptacle, or the connector if an extension cord is used, to prevent water traveling along the cord and coming in contact with the receptacle.

To reduce the risk of electrocution, ! DANGER DoN’T unplug the cord if the plug or

receptacle gets wet. Disconnect the fuse or circuit breaker that supplies power to the tool. Then unplug and examine for presence of water in the receptacle.








“SaVe TheSe iNSTRUcTioNS”


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“READ ALL INSTRUCTIONS” — Failure to follow the SAFETY RULES identified by BULLET (•) symbol listed


BELOW and other safety precautions, may result in serious personal injury.



If any part of your saw is missing, malfunctioning, has been damaged or broken … such as the motor switch, or other operating control, a safety device or the power cord … cease operating immediately until the particular part is properly repaired or replaced.

NEVER place your face or body in line with the cutting tool.

NEVER place your fingers and hands in the path of the sawblade or other cutting tool.

DO NOT perform any operation “FREEHAND” — always use the fence to position and guide the work for both rip cuts and crosscuts.

Provide adequate support to the rear and sides of the saw table for wider or long workpieces.

If you stall or jam the tile blade in the workpiece, turn saw “OFF”, remove the workpiece from the tile blade, and check to see if the tile blade is parallel to the table slots or grooves and if the riving knife is in proper alignment with the sawblade. If ripping at the time, check to see if rip fence is parallel with the sawblade. Readjust as indicated.

DO NOT remove small pieces of cut-offmaterial that may become trapped inside the blade guard while the saw is running. This could endanger your hands or cause a kick back. Turn saw “OFF” and wait until blade stops.


Dull, gummy or improperly sharpened or set cutting tools can cause material to stick, jam, stall the saw, or kickback at the operator. Minimize potential injury by proper cutting tool and machine maintenance. NEVER ATTEMPT TO FREE A STALLED SAWBLADE WITHOUT FIRST TURNING THE SAW OFF.

•NEVER use toothed blade on the tile saw.

•Make sure the cutting tool rotates in the same direction as the rotation arrow on the upper guard. Also make sure the cutting tool, arbor collars and arbor nut are installed pro perly. Keep the cutting tool as low as possible for the oper ation being performed. Keep all guards in place whenever possible.

Do not use any blade or other cutting tool marked for an operating speed less than 3600 R.P.M. Never use a cutting tool larger in diameter than the diameter for which the saw was designed.

“SaVe TheSe iNSTRUcTioNS”


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“READ ALL INSTRUCTIONS” — Failure to follow the SAFETY RULES identified by BULLET (•) symbol listed


BELOW and other safety precautions, may result in serious personal injury.

Do not allow familiarity gained from frequent use of your tile saw to become commonplace. Always remember that a careless fraction of a second is sufficient to inflict severe injury.


The waRNiNGS ShowN Below caN Be foUND oN YoUR Tool. TheSe waRNiNGS aRe oNlY a ! WARNING coNDeNSeD foRm of The moRe DeTaileD SafeTY RUleS aND pRecaUTioNS ThaT appeaR iN

YoUR owNeR’S maNUal. TheY SeRVe aS a RemiNDeR of all SafeTY RUleS NeeDeD foR Safe opeRaTioN of ThiS Tile Saw.

“SaVe TheSe iNSTRUcTioNS”


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“READ ALL INSTRUCTIONS” — Failure to follow the SAFETY RULES identified by BULLET (•) symbol listed


BELOW and other safety precautions, may result in serious personal injury.



Motor Specifications

In the event of a malfunction or breakdown, grounding provides a path of least resistance for electric current to reduce the risk of electric shock. This tool is equipped with an electric cord having an equipment-groundingconductor and a grounding plug. The plug must be plugged into a matching outlet that is properly installed and grounded in accordance with all local codes and ordinances. This saw is wired for operation on110-120volts, 60 Hz. alternating current. Before connecting the motor cord to power source, make certain the switch is in the “OFF” position and be sure the electric current is of the same characteristics as stamped on the tile saw nameplate.

Connection To A Power Source

This machine must be grounded while in use to protect the operator from electric shock.

Plug power cord into a 110-120Vproperly grounded GFCI type outlet protected by a15-ampdual element time delay fuse or circuit breaker.

Not all outlets are properly grounded. If you are not sure that your outlet, as pictured on this page, is properly grounded; have it checked by a qualified electrician.

To avoid electric shock, do not touch the ! DANGER metal prongs on the plug when installing or

removing the plug to or from the outlet.

Failure to properly ground this power tool ! DANGER can cause electrocution or serious shock, particularly when used near metal plumbing or other metal objects. If shocked, your reaction could cause your hands to

hit the tool.

If power cord is worn, cut or damaged in ! DANGER any way, have it replaced immediately to

avoid shock or fire hazard.

Your unit is for use on 120 volts and is equipped with a 3-conductorcord and grounding type plug, approved by Underwriters Laboratories and the Canadian Standards Association. The ground conductor has a green jacket and is attached to the tool housing at one end and to the ground prong in the attachment plug at the other end.

If the outlet you are planning to use for this power tool is of the two-prongtype, DO NOT REMOVE OR ALTER THE GROUNDING PRONG IN ANY MANNER. Have a qualified electrician replace theTWO-prongoutlet with a properly groundedTHREE-prongoutlet.

Improper connection of the equipment-groundingconductor can result in a risk of electric shock. The conductor with insulation having an outer surface that is green with or without yellow stripes is the equipment grounding conductor. If repair or replacement of the electric cord or plug is necessary, do not connect the equipment grounding conductor to a live terminal.

Check with a qualified electrician or service personnel if the grounding instructions are not completely understood, or if in doubt as to whether the tool is properly grounded.

Extension Cords

Always use proper extension cord. The use of any extension cord will cause some loss of power. To keep this to a minimum and to prevent overheating and motor burn-out,use the table below to determine the minimum wire size (A.W.G.) extension cord. Use only3-wireextension cords which have3-pronggrounding type plugs and3-polereceptacles which accept the tool’s plug. Make sure your extension cord is in good condition.

Use only extension cords that are intended for outdoor use. These extension cords are identified by a marking “Acceptable for use with outdoor appliances, store indoors while not in use.” Use only extension cords having an electrical rating equal to or greater than the rating of the product. Do not use damaged extension cords. Examine the extension cord before using, and replace it if it is damaged. Do not abuse extension cords, and do not yank on any cord to disconnect it. Keep the cord away from heat and sharp edges. Always disconnect the extension cord from the receptacle before disconnecting the product from the extension cord.

Replace damaged cords immediately. Use of damaged cords can shock, burn or electrocute.

If an extension cord is necessary, a cord with adequate size conductors should be used to prevent excessive voltage drop, loss of power or overheating. The table shows the correct size to use, depending on cord length and nameplate amperage rating of tool. If in doubt, use the next heavier gauge. Always use U.L. and CSA listed extension cords.



120 Volt A.C. Tools Cord Length

Ampere Rating

in Feet Cord Size in A.W.G.







































NOTE: The smaller the gauge number, the heavier the cord.

“SaVe TheSe iNSTRUcTioNS”


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Table of contents

General Safety Rules................................................


Additional Safety Rules..........................................


Motor Specifications and Electrical Requirements....7

Table of Contents......................................................


Glossary of Terms ....................................................


Unpacking and Checking Contents ..........................


Getting to Know Your Tile Saw ..............................


Assembly and Adjustments ..............................


Tile Blade Installation ..........................................


Top Guard Installation ........................................


Top Guard Alignment ..........................................


Operation ..........................................................


Filling the Water Trough ......................................


Starting and Stopping ..........................................


Making a Flat Cut ................................................


Making a Miter Cut ..............................................


Making a Bevel Cut ............................................


After Use..............................................................


Maintaining Your Tile Saw ......................................


Troubleshooting ......................................................


Glossary of Terms


The item on which the cutting operation is being performed. The surfaces of a workpiece are commonly referred to as faces, ends and edges.


The shaft on which a cutting tool is mounted.


A cutting or shaping operation made across the width of the workpiece cutting the workpiece to length.


Performing a cut without a fence, miter gauge, fixture, hold down or other proper device to keep the workpiece from twisting during the cut.

leaDiNG eND

The end of the workpiece which, during a rip type operation, is pushed into the cutting tool first.


A cutting operation along the length of the workpiece cutting the workpiece to width.

ReVolUTioNS peR miNUTe (R.p.m.)

The number of turns completed by a spinning object in one minute.


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Unpacking and checking contents

To reduce the risk of injury, never ! WARNING connect plug to power source outlet until

all assembly steps are complete and until you have read and understood the entire owner’s manual.

Model 3540 Tile Saw is shipped complete in one box.

Unpacking and Checking Contents. Separate all parts from packing materials and check each one with the “Table of Loose Parts” to make sure all items are accounted for before discarding any packing material.



if any parts are missing, do not at tempt

to assemble the saw, plug in power cord

or turn the switch on until the missing parts are



obtained and are installed correctly.


Table of loose parts






Tile Saw




Rip Fence




Miter Gauge




Nut Wrench




Motor Shaft Wrench




Tile Blade




Top Guard




Top Guard Arm



additional Tools Needed for assembly




Phillips Head





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Getting To Know Your Tile Saw





































Top Guard



Top Guard Arm



Tile Blade



Ripping Scale



Lower Guard



Water Trough



Bevel Cutting Adjustment Knob



On / Off Switch



Fence Locking Knob






Miter Gauge



Tile Blade Wrenches






Cord Wrap