Bosch 4212L User Manual

BM 2610924645 08-04 E 9/2/04 10:48 AM Page 1

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Operating/Safety Instructions

Instrucciones de funcionamiento y seguridad Consignes de fonctionnement/sécurité

4212L

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Table of Contents

Safety...................................................................	3-7
General Safety Rules for Bench Top Tools ..........	3
Safety Rules for Miter Saws..............................	4-7
Electrical Requirements........................................	7
Getting To Know Your Miter Saw ......................	8-9
Unpacking & Checking Contents.......................	10
Tools for Assembly & Alignment .......................	10
Assembly .........................................................	11-12
Installation & Removal of the Blade ...................	11
Attaching Miter Lock Knob .................................	12
Assembling Dust Elbow & Dust Bag ..................	12
Adjustments....................................................	13-17
Checking 0° Bevel Adjustment ...........................	13
Right 45° Bevel Stop ..........................................	14
Left 45° Bevel Stop ............................................	15
Adjusting Bevel Lock Lever Tension ..................	15
Blade Square to Fence ......................................	16
Miter Scale Indicator Adjustment........................	17
Kerf Insert...........................................................	17
Transporting, Placement & Mounting...........	18-19
Lifting the Saw....................................................	18
Mounting Applications ...................................	18-19
Adjusting the Four Position Switch Handle ........	19
Basic Saw Operations....................................	20-24
Body and Hand Position.....................................	20

Workpiece Support........................................	21-22
Switch Activation ................................................	23
Detent Override ..................................................	23
Sliding Base and Fence Extensions...................	24
Saw Operations ..............................................	25-32
Miter Cut.............................................................	25
Bevel Cut.......................................................	26-27
Compound Cuts .................................................	27
Flip-Up Crown Stops/Length Stop......................	28
Cutting Base Molding .........................................	29
Cutting Crown Molding..................................	29-31
Special Cuts .......................................................	32
Maintenance & Lubrication ...........................	33-34
Carbon Brushes .................................................	33
Belt Replacement ...............................................	33
Cleaning .............................................................	33
Care of Blades....................................................	34
Tool Lubrication ..................................................	34
Bearing ...............................................................	34
Troubleshooting .............................................	34-35
Electrical Troubleshooting ..................................	34
General Troubleshooting ....................................	35
Accessories..........................................................	36
Warranty..............................................................	112

2.

		Safety
		“READ ALL INSTRUCTIONS” — Failure to follow the SAFETY RULES identified by BULLET (●) symbol
	! WARNING
		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 pad lock, 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.

●Double insulated tools are equipped with a polarized plug (one blade is wider than the other). This plug will fit in a polarized outlet only one way. If the plug does not fit fully in the outlet, reverse the plug. If it still does not fit, contact a qualified electrician to install a polarized outlet. Do not change the plug in any way. Double insulation eliminates the need for the three wire grounded power cord and grounded power supply.

●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.

●When operating a power tool outside, 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 non-skid 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.

“SAVE THESE INSTRUCTIONS”

3.

Safety

! WARNING “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.

●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.

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 - for example; do not use the miter saw for slicing meats.

●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.

Service

●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 Miter Saws

●Use clamps to support workpiece whenever possible. If supporting the workpiece by hand, you must always keep hand outside of “No Hand” area as marked with a symbol on the base. Do not use this saw to cut pieces that are too small to be securely clamped.

Your hand if placed inside the “No Hands” region can easily slip or be pulled into the blade.

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

●Never cross your hand over intended line of cutting. Supporting the workpiece “cross handed” i.e. holding the left side of the workpiece with your right hand is very dangerous.

●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.

●Miter saws are intended to cut wood or woodlike products, they cannot be used with abrasive cutoff wheels for cutting ferrous material such as bars, rods, studs, etc. However, if cutting materials like aluminum or other non-ferrous metals, use only saw blades specifically recommended for nonferrous metal cutting. Cutting ferrous materals causes excessive sparking and will damage the lower guard and will overload the motor.

(NOTE: Bosch Tool Corporation does not offer 12” metal cutting blades.)

“SAVE THESE INSTRUCTIONS”

4.

Safety

! WARNING “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.

●Inspect your workpiece before cutting. If workpiece is bowed or warped, clamp it with the outside bowed face toward the fence. Always make certain that there is no gap between the workpiece, fence and table along the line of the cut. Bent or warped workpieces can twist or rock and may cause binding on the spinning saw blade while cutting. Also, make sure there are no nails or foreign objects in the workpiece.

●Do not use the saw until the table is clear of all tools, wood scraps, etc., except the workpiece. Small debris or loose pieces of wood or other objects that contact the revolving blade can be thrown with high speed at the operator.

●Do not feed workpiece into the blade or cut “freehand” in any way. Workpiece must be stationary and clamped or braced by your hand. Saw must be fed through the workpiece smoothly and at a rate which will not overload the saw’s motor.

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

●Plan your work. Provide adequate support accessories such as tables, saw horses, table extension, etc. for workpieces wider or longer than the table top (see page 21). Workpieces longer or wider than the miter saw table can tip if not securely supported. If the cutoff piece or workpiece tips it can lift the lower guard or be thrown by the spinning blade.

●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 blade.

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

●Always use a clamp or a fixture designed to properly support round material such as dowel rods, or tubing. Rods have a tendency to roll while being cut, causing the blade to “bite” and pull the work with your hand into the blade.

●When cutting irregularly shaped workpieces, plan your work so it will not slip and pinch the blade and be torn from your hand.

A piece of molding, for example, must lie flat or be held by a fixture or jig that will not let it twist, rock or slip while being cut.

●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 miter saw “OFF” by releasing switch. Wait for all moving parts to stop and unplug the miter saw, then work to free the jammed material. Continued sawing with jammed workpiece could cause loss of control or damage to miter saw.

●Braking action of the saw causes the saw head to jerk downward. Be ready for this reaction when making an incomplete cut or when releasing the switch before the head is completely in the down position.

●After finishing the cut, release the switch, hold the saw arm down and wait for blade to stop before removing work or cutoff piece. If blade does not stop within five (5) seconds, unplug the saw and follow the instructions in the Troubleshooting section.

REACHING WITH YOUR HAND UNDER A COASTING BLADE IS DANGEROUS!

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

●For chop action cutting, turn the saw “ON” and lower the head assembly to make the cut. Release the switch and wait for the blade to completely stop before raising the head assembly and removing the workpiece.

“SAVE THESE INSTRUCTIONS” 5.

! WARNING

! WARNING

Safety

! WARNING “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 miter saw to become commonplace. Always remember that a careless fraction of a second is sufficient to inflict severe injury.

●THINK SAFETY! SAFETY IS A COMBINATION OF OPERATOR’S COMMON SENSE, KNOWLEDGE OF THE SAFETY AND OPERATING INSTRUCTIONS AND ALERTNESS AT ALL TIMES WHEN THE MITER SAW IS BEING USED.

THE WARNINGS SHOWN

BELOW CAN BE FOUND ON YOUR TOOL. THESE WARNINGS ARE ONLY A 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 MITER SAW.

Some dust created by power sanding, 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-based paints,

•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.

DESIGNATED DANGER ZONE. AVOID POSITIONING HANDS, FINGERS OR ARMS IN THE AREA DESIGNATED BY THIS SYMBOL.

“SAVE THESE INSTRUCTIONS” 6.

! WARNING

Safety

“READ ALL INSTRUCTIONS” — Failure to follow the SAFETY RULES identified by BULLET (●) symbol list- ! WARNING ed BELOW and other safety precautions, may result in serious personal injury.

Double Insulated Tools

Extension Cords

Double insulation is a design concept used in electric power tools which eliminates the need for the three wire grounded power cord and grounded power supply system. It is a recognized and approved system by Underwriter’s Laboratories, CSA and Federal OSHA authorities.

●Servicing of a tool with double insulation require care and knowledge of the system and should be performed only by a qualified service technician.

●WHEN SERVICING, USE ONLY IDENTICAL REPLACEMENT PARTS.

●POLARIZED PLUGS. Your tool is equipped with a polarized plug (one blade is wider than the other), this plug will fit in a polarized outlet only one way. If the plug does not fit fully in the outlet, reverse the plug. If it still does not fit, contact a qualified electrician to install the proper outlet. To reduce the risk of electrical shock, do not change the plug in any way.

“SAVE THESE INSTRUCTIONS”

●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.

RECOMMENDED SIZES OF EXTENSION CORDS

Tools		120 Volt A.C. Tools
Ampere		Cord Length in Feet
Rating		Cord Size in A.W.G.
	25	50	100	150
3-6	18	16	16	14
6-8	18	16	14	12
8-10	18	16	14	12
10-12	16	16	14	12
12-16	14	12	N/A	N/A

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

Electrical Requirements

1.Connect this saw to a 120V, 15-amp branch cicuit with a 15-amp time delay fuse or circuit breaker. Using the wrong size fuse can damage the motor.

2.Fuses may “blow” or circuit breakers may trip frequently if motor is overloaded. Overloading can occur if you feed the blade into the workpiece too rapidly or start and stop too often in a short time.

3.Most motor troubles may be traced to loose or incorrect connections, overload, low voltage (such as small size wire in the supply circuit or too overly long supply circuit wire). Always check the connections, the load and the supply circuit whenever motor does not work well.

Electric Brake

Your saw is equipped with an automatic electric brake which is designed to stop the blade from spinning in about five (5) seconds after you release the trigger switch. It is useful when making certain cuts in wood where a coasting blade would result in a wide, imprecise cut.

When electrical power is lost due to ! WARNING blown fuse or other causes, the

motor will gradually slow down and the braking action is initiated ONLY by the release of the trigger switch.

The electric blade brake of your miter saw has been designed for highest degree of reliability, but unexpected circumstances such as contamination on the commutator and brushes or failure of motor’s components can cause the brake not to activate. If this condition occurs, turn the saw “ON” and “OFF” four to five times without contacting the workpiece. If the tool operates but the brake does not consistently stop the blade in about five (5) seconds, DO NOT use saw and have it serviced immediately.

The brake action of this saw is not intended as a safety feature.

Remember to let the saw blade come to a complete stop before raising the blade from the workpiece. As always the guard system is your best protection against unintentional contact with a spinning saw blade. NEVER wedge open or defeat the closing action of the lower guard.

7.

Getting To Know Your Miter Saw

! WARNING To avoid injury from accidental starting, remove plug from power source

outlet before making any adjustments.

1.Main Handle – This handle contains the power switch. Pulling this handle down lowers the blade into the workpiece.

2.Switch Lock-Off Release Button – One of these two buttons must be pressed before the power switch can be pressed.

3.Power Switch – The power switch used with the “Lock-OFF” button energizes the unit.

4.Lower Blade Guard – The lower blade guard helps protect your hands from the spinning blade. It retracts as the blade is lowered.

5.Lower Guard Lip – Lip can be used to raise the lower guard when guard becomes jammed on a workpiece.

6.Blade – Use only 12" blades with 1" arbor hole.

7.Sliding Fence – Supports the workpiece. The fence has a cast in scale to make repetitive cuts easy. The fence also has holes to secure an auxiliary fence if desired.

8.Kerf Insert – Kerf inserts can be adjusted to different blade widths to minimize workpiece tear-out.

9.Miter Scale/Miter Angle Indicator – This scale is cast in on the base of the saw. Indicator is fastened to the table.

10.Miter Detent Override – Allows detent action to be locked out allowing for micro adjustments to any miter angle.

11.Miter Lock Knob – The miter lock knob locks the miter saw table at any desired miter angle.

12.Miter Detent Lever – The lever releases the table from the detent.

13.Bevel Lock Lever – The front-positioned bevel lock lever locks the head assembly at the desired bevel angle.

14.Miter Detents – There are ten (10) miter detent slots for fast and accurate miter cuts of common miter angles.

15.Table – Sits in base, provides workpiece support, rotates for desired miter cuts and rotates the head assembly. The front extended part of the table is called the miter arm.

16.Base – Provides working surface to support workpiece.

17.Tool Mounting Pads – The four corners of the saw provide areas to clamp, bolt or nail the saw to a flat work surface.

18.Sliding Base Extensions – These extensions provide extra workpiece support and are especially useful when cutting long workpieces.

19.Base Extension Clamping Levers – Locks the base extensions at desired positions.

20.Head Assembly Lock Pin – Used to lock the head assembly in the lower position for transporting.

21.Lower Guard Actuation Link – Allows for smooth movement of the lower guard.

22.Brush Caps – These caps keep the motor brushes in position and provide easy access for inspecting and replacing brushes.

23.Handle Clamp – Locks handle in the selected position.

24.Handle Rotation Release Lever – Pulling this lever allows the handle to be rotated. Release the lever into one of four operating positions.

25.Front Carrying Handle – Used for lifting the tool.

26.Drive Belt Cover – Access to drive belt.

27.Dust Port – The dust port can accommodate the dust chute and dust bag or optional VAC004 Vacuum Hose Adapter, which accepts Bosch 35mm hoses.

28.Power Cord – Supplies power to motor.

29.Bevel Scale – This scale is large and angled to allow you to easily read bevel angles.

30.Bevel Detent Pin (Crown Molding Setting) –

Allows you to easily lock the head assembly to the bevel angle of 33.9° to the left or right.

31.Workpiece Clamp Position Holes – There are two (2) holes (not shown) behind the fence for placing the clamp.

32.Sliding Fence Lock Knob – Used to hold fence position after slide adjustment.

33.Bevel Range Selector Knob – Allows selection of the bevel range, 0° to 45° left, 0° to 45° right, and complete range of 47° left to 46° right.

34.Arbor Lock—Keeps the blade from rotating while tightening or loosening arbor screw during blade replacement or removal.

35.Upper Blade Guard – Covers upper portion of the blade.

36.Dust Bag and Dust Elbow – Used to collect saw dust.

37.Workpiece Clamp – Used to secure a workpiece on either base side.

38.Flip-Up Crown Stops/Length Stop – Used to hold crown molding angled to the table. / For repetitive cuts of the same length.

39.Arbor Laser / 3x Battery.

8.

							1
							2
		22				3	39
							5
							4
		21					6
	20						7
							8
							9
							10
	18						11
		17	16	15	14	13	12
	19
			23
				24			36
	35				25
						26
	34					27	37
						28
			45			29
			33
			.9
						30	38
						31
						32
	33
					9.

Unpacking & Checking Contents

Before moving the saw: Lock the ! WARNING miter lock knob in 60° position. Lock

bevel lock handle. Lock head assembly in the down position.

Never carry the tool by the cord or head assembly power switch handle. Damage to insulation could cause an electric shock. Damage to wire connections could cause a fire.

Your new Model Miter Saw is shipped complete in one box, But you may need to make some adjustments and alignments before cutting final workpieces.

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

Check List of Loose Parts:

■ Clamp (Item #37 on page 8)

■ Flip-Up Crown Stops (2) (Item #38 on page 8)

■ Dust Elbow/Dust Bag (Item #36 on page 8)

■ Multi Purpose Tool (See below)

■ Miter Lock Knob (Item #11 on page 8)

■ 3mm Hex “L” Wrench (See below)

■ 10mm/17mm Combination Open-End Wrench

(See below)

■ Arbor Laser / 3x Battery / Arbor Laser Manual

! WARNING If any parts are missing, do not plug in power cord or turn the switch on

until the missing parts are obtained and are installed correctly.

Tools for Assembly & Alignment

Multi-Purpose Tool with Bit (4mm/Philips #2)

(supplied, stored on the right rear base)

Combination Square (not included)

1

2

3

Combination Square Must be True

1.Use the straight edge of a 3/4" thick board (this edge must be perfectly straight).

2.Draw a line on the board along this edge.

3.There should be no gap or overlap when the square is flipped over in dotted position.

10mm/17mm Combination Open End Wrench

(supplied)

3mm Hex “L” Wrench

(supplied)

10.

! WARNING

Assembly

Installation And Removal Of The Blade

Disconnect plug from power source before performing any assembly,

adjustment or repair to avoid possible injury.

1. The miter saw is equipped with a lock pin used to lock the miter saw in the lowered position. To release, push the handle down slightly and pull the lock pin to its full out position and rotate 90°.

NOTE: If there is difficulty in pulling the lock pin out, you may need to adjust the depth stop bolt so the handle can be pushed down.

2. Loosen, but do not remove, both cover plate screws (front and rear). (Figure 1)

3. Lift the lower guard and the cover plate so the blade bolt is exposed (Figure 1).

4. Remove blade bolt by pressing the arbor lock (Item #34 on page 9) while turning bolt clockwise using the multi purpose tool.

NOTE: The blade bolt has left hand threading.

5. Remove the blade bolt, outer washer and the blade. Do not remove inner washer (Figure 2).

6. To install the 12" blade, fit blade between the chip deflectors and onto the arbor shaft, and onto 1" shoulder on the inner washer (Figure 2).

NOTE: Make sure the rotation arrow on the blade matches the clockwise rotation arrow on the lower guard.

! WARNING To avoid injury, do not use a blade larger or smaller than 12" diameter

and 1" arbor. Smaller blades will not cut workpiece all the way through and larger blades will cut into table and/or blade guards.

7. Replace the outer washer in it’s proper orientation and tighten blade bolt finger tight.

8. Press the arbor lock and tighten blade bolt securely, but do not overtighten.

9. Rotate cover plate to its original position and tighten both cover plate screws.

! WARNING Never use saw without cover plate securely in place. Lower

guard will not function properly.

10.Be sure the arbor lock is released so the blade turns freely.

After installing a new blade, make ! WARNING sure the blade does not interfere

with the table insert at the 0° and 45° bevel positions. Lower the blade into the table slot and check for any contact with the base or turn table structure. If blade contacts base or table, seek authorized service.

Lower Guard

Cover Plate

Outer

Washer

	Front & Rear
Blade Bolt	Cover Plate Screws

Figure 1. Blade Removal

Outer Washer	Sawblade

Inner

Washer

Blade Bolt

(Left Hand Thread)

Shoulder

Figure 2. Blade Hardware

Inner

Washer

Upper	Arbor
Guard	Shaft

Figure 3. Blade Installation

11.

! WARNING

Assembly (continued)

Attaching Miter Lock Knob

Locate the miter gauge lock knob from among the loose parts, and thread shaft into miter detent assembly as shown in illustration.

Miter Gauge

Lock Knob

Shaft

Figure: Miter Lock Knob

Assembling Dust Elbow

And Dust Bag

1.With the miter arm locked in the down position, push the dust elbow onto the dust port. Push the dust bag onto the elbow and rotate both to desired position.

2.Position dust chute/bag so that it does not interfere with the tool during the cutting operation for all miter/bevel settings.

3.The dust bag requires emptying when full of sawdust. Empty it frequently and after completion of sawing. Carefully remove dust bag from dust

elbow. Empty dust bag in proper trash bin by unzipping the bag. Be extremely careful of dust disposed, materials in fine particle form may be explosive. Do not throw sawdust on an open fire. Spontaneous combustion, may in time, result from mixture of oil or water with dust particles.

DUST PORT – The dust port can accommodate the dust chute and dust bag or optional VAC004 Vacuum Hose Adapter, which accepts Bosch 35mm hoses.

When sawing chemically pressure treated lumber, paint that may be lead based, or any other materials that may contain

carcinogens, use special precautions. A suitable respirator must be worn by all personnel entering the work area. Work area should be sealed by plastic sheeting and persons not protected should be kept out until work area is thoroughly cleaned.

Dust Bag	Dust
	Port

Dust

Elbow	BEVEL	0º
	STOPS:	RIGHT 45º

Figure: Dust Elbow and Dust Bag

12.

! WARNING

Adjustments

Disconnect plug from power source before performing any assembly,

adjustment or repair to avoid possible injury.

NOTE: Your miter saw was completely adjusted at the factory. However, during shipment, slight misalignment may have occurred. Check the following settings and adjust if necessary prior to using this miter saw.

Checking 0° Bevel

Adjustment

1.Lower head assembly and engage head assembly lock pin.

2.Rotate table to 0° miter position

3.Pull up bevel lock lever to unlock bevel.

4.Check position of bevel range selector knob, it should be at the 0°-45° position.

5.Tilt the saw assembly to the left, then rotate saw assembly to the right until you feel the stop in the vertical position. This is where the saw is currently set for the 0° bevel cut.

Use a combination square to check blade squareness to the table. Place the square on the table and press it against the blade. If the blade does not contact the full length of the square, (figure 1), follow the calibrating procedure.

Blade

Combination

Square Bevel Lock

Lever

Figure 1. Blade Square to Table

Calibrating Blade at 0°

(90° to the table)

NOTE: Calibrating the bevel setting also automatically calibrates the 33.9° stops.

1.Remove rear cover to expose bolts.

2.Lift bevel lock lever to release bevel lock.

3.Loosen bolt heads “A” and “B” with 10 mm openend wrench at least one full turn (Figure 2a).

A

B

E

D

Figure 2a. Calibrating Blade at 0 degrees (90° to the table)

4.Place 4 mm Allen wrench bit onto multi-purpose tool and loosen setscrew “D” at least 3 full turns (Figure 2b).

5.Place combination square on table against blade. (See Figure 1)

6.Use 3 mm hex wrench supplied, and insert it in the hex screw through the hole marked “0” deg”. Rotate the wrench and watch the saw blade tilt until it is aligned with combination square.

7.Tighten setscrew “D”.

8.Tighten 10 mm bolt heada “A” and “B”.

9.Check and adjust bevel pointer to 0 degrees on each side of bevel scale.

10.Push down bevel lock lever until you feel the lever snap into the locked position.

3mm “L” Wrench in

0° Access

Hole

Bevel

Pointer

Figure 2b. Calibrating Blade at 0 degrees (90° to the table)

13.

! WARNING

Adjustments (continued)

Disconnect plug from power source before performing any assembly,

adjustment or repair to avoid possible injury.

Checking Right 45°

Bevel Stop

1.Lower head assembly and engage head assembly lock pin.

2.Rotate table to the 0° miter position.

3.Pull up bevel lock lever to unlock bevel.

4.Move bevel range selector knob to “0°-45° Right” position. (See page 26)

5.Tilt the saw to the right until you feel the stop in the 45° right position. This is where the saw is currently set for the 45° right bevel cut.

6.Use a combination square to check blade at the 45° stop. Place the combination square head on the table and press it’s 45° surface against the blade. If the blade does not contact the full length of the square, (figure 1), follow the calibrating procedure.

Combination

Square

Figure 1. Right 45° Bevel Stop

Calibrating Right 45°

Bevel Stop

1.Lift bevel lock lever to release bevel lock.

2.Tilt saw to 45° right bevel position.

3.Position combination square with 45° surface against blade. (Figure 1)

4.Insert 3 mm “L” wrench into Right 45° hole in vertical support frame. (Figure 2)

5.Rotate “L” wrench while viewing blade against combination square until it matches 45° surface.

6.Adjust bevel pointer to 45° line on bevel scale.

3mm “L” Wrench in Right 45° Access Hole

Bevel

Pointer

Figure 2. Right 45° Bevel Adjustment

14.

Checking Left 45°

Bevel Stop

1.Lower head assembly and engage head assembly lock pin.

2.Rotate table to the 0° miter position.

3.Pull up bevel lock lever to unlock bevel.

4.Move bevel range selector knob to 45°-0° position. (See page 26)

5.Tilt the saw assembly to the left, then rotate saw assembly to the right until you feel the stop in the 45° left position. This is where the saw is currently set for the 45° left bevel cut.

6.Use the head (remove ruler) of a combination square to check blade at the 45° stop. Place the combination square head on the table and press it’s 45° surface against the blade. If the blade does not contact the full length of the square, (figure 1), follow the calibrating procedure.

Blade

Table	Bevel Lock
Combination Square	Lever

Figure 1. Left 45° Bevel Stop

Calibrating Left 45°

Bevel Stop

1.Remove rear cover to expose bolts.

2.Lift bevel lock lever to release bevel lock.

3.Tilt saw to 45° left bevel position.

4.Remove the ruler from the combination square and position with 45° surface against blade. (Figure 1)

5.Place 10mm open-end wrench on bolt head “F”. While rotating bolt “F”, watch blade tilt movement until it is aligned with the 45° surface on combination square. (Figure 2)

6.Adjust bevel pointer to 45° line on bevel scale.

Adjusting Bevel Lock

Lever Tension

1.Lift bevel lock lever to release bevel lock.

2.Place 17mm open-end flat wrench on bolt head “E” (Figure 2).

3.Turn nut “E” clockwise 1/8 turn to tighten bevel lock tension or turn counter-clockwise to 1/8 turn to loosen bevel lock tension.

4.Push down bevel lock lever until you feel the lever snap into the locked position.

5.Verify that bevel lock tension holds the bevel position secure and also allows bevel lock lever to lock down to the point that a solid stop is felt.

6.If necessary, repeat steps 1–5 to adjust the tension.

E

F

Figure 2. Left 45° Bevel Adjustment

15.

! WARNING

Adjustments (continued)

Disconnect plug from power source before performing any assembly,

adjustment or repair to avoid possible injury.

Blade Square to Fence

1.Lower head assembly and engage head assembly lock pin.

2.Set table at the 0° miter position and tighten miter lock knob.

3.Place combination square against fence with ruler of square paralel to blade. Ruler should contact blade, but not blade teeth. If blade is not square against ruler, follow the fence alignment procedure. (Figure 1)

Fence Alignment

a.Remove both fences by loosen fence knob, slide fence to full in position, and pull up on fence.

b.The head assembly should remain in lowered position.

c.Loosen the four (4) hex bolts behind fence using multi purpose wrench (Figure 2).

d.Adjust fence until blade and fence have full contact with the square.

e.Tighten the four (4) hex bolts.

f.Re-attach sliding fence.

Fence

Blade

Combination

Square

Figure 1. Blade Square to Fence

Hex Fence

Fence Hex Bolts Knob

Knob Bolts

Figure 2. Fence Adjustment

16.

Miter Scale

Indicator Adjustment

1.Set table at the 0° miter position and tighten miter lock knob.

2.Raise the head assembly to the full-up position.

3.Loosen the Phillips screw that holds the indicator in place.

4.Position the indicator to align with the 0° miter mark and tighten the screw.

Screw
Access	Phillips
Hole	Screwdriver

Miter

Scale

Indicator

Figure: Miter Scale Adjustment

Kerf Insert Replacement

The kerf insert should be close to the blade, in order to avoid tear-out on the bottom of the workpiece.

To Replace Kerf Insert:

1.Raise the head assembly.

2.Loosen the six (6) kerf screws using the multi purpose tool.

3.Replace kerf insert.

4.Tighten the kerf screws.

NOTE: A new kerf insert does not have a blade slot. The slot will be created by the tool’s blade. After tightening the kerf screws, switch the saw on and fully lower the blade into the kerf insert, thereby creating a blade slot. A “zero-clearance” kerf insert support to the workpiece, will greatly reduce splintering.

17.

Screws

Kerf

Insert

Figure: Kerf Insert

! CAUTION

Transporting, Placement & Mounting

To avoid injury always observe the ! WARNING following:

• Unplug electric cord. Before transporting the saw, rotate head and lock assembly to 60° right miter, lock into detent, and lock the head assembly in the lowered position.

Lifting Saw

•To avoid back injury, hold the tool close to your body when lifting. Bend your knees so you can lift with your legs, not your back.

•Lift by using the cast-in carry handles at each side of the bottom of the base.

•Alternate lifting method: When picking tool up from ground, use rear carrying handle and front carrying handle (above guard).

•Never lift tool by holding main switch handle. This may cause serious damage.

•Never carry the miter saw by the power cord or the operational handle. Attempting to lift or carry the tool by the power cord will damage the insulation and the wire connections resulting in electric shock or fire.

•Observe the position of the saw. People standing behind it could be injured by thrown debris.

•Place the saw on a firm, level surface where there is plenty of room for handling and properly supporting the workpiece.

•Bolt, nail or clamp the saw to its support.

Be careful not to over-drive nail or over-torque the bolt. This could

crack foot or damage base.

Mounting Applications

Mounting to Workbench

Mount the saw using either the four bolt holes (5/16") or the four nail holes to the workbench. Check for clearance to the left and right of the saw.

1. Each of the four mounting holes should be bolted securely using 5/16" bolts, lock washers, and hex nuts (not included).

2. Locate and mark where the saw is to be mounted.

3.Drill four (4) 5/16" diameter holes through workbench.

4. Place the miter saw on the workbench aligning holes in base with holes drilled in workbench. Install bolts, lock washers and hex nuts. As an alternative, you can mount the saw using drywall screws in the four nail holes.

Supporting surface where saw is to be mounted should be examined carefully after mounting to ensure that no movement can occur during use. If any tipping or walking is noted, secure the workbench or stand before operating the compound miter saw.

Figure: Workbench Mounting

18.

Mounting Applications

Portable Mounting Using Clamps

If necessary, clamp the miter saw to a workbench or table top by placing two (2) or more “C” clamps on the clamping areas and secure.

NOTE: Be careful not to place clamps over the base extension clamping levers.

Mounting with clamps will prevent access to some wide miter angles.

Clamps

Figure: Portable Mounting Using Clamps

Adjusting the Four Position Switch Handle

Handle

Lock

Clamp

Handle

Rotation

Release

Lever

a.

b.

c.

d.

Figure: Setting Main Handle Position

Setting Main Handle in

Desired Position

The switch handle can be positioned in any of four different orientations, depending on the cutting situation and user preference:

a. Vertical b. 45° Left c. Horizontal d. 45° Right

To reposition the main handle:

1.Release handle lock clamp.

2.Pull and hold handle rotation release lever

3.Rotate handle to desired location.

4.Let go over release lever to set handle into place. Release lever will retract down only in one of the four (4) positions.

Note: Power switch can not be actuated unless release lever is retracted down. Do not attempt to

switch tool on between handle position, damage may occur.

5. Lock the handle clamp.

Adjusting the Four-Position

Handle Lock Clamp Tension

1.Open handle lock clamp.

2.Locate the two setscrews at the end of the handle clamp.

3.To increase tension, use 1.5 mm Allen wrench and rotate both setscrews to the right. To decrease tension, rotate both setscrews to the left.

Note: Always adjust both setscrews by the same amount.

4.Close handle lock clamp.

5.Check the tension.

19.

! WARNING

! WARNING

Basic Saw Operations

Body and Hand Position

Position your body and hands properly to make cutting easier and

safer. Observe the following instructions (Figure 1).

Correct

Incorrect Use

Figure 1. Hand Positions

•Never place hands near cutting area. Keep hands and arms outside the “No Hands” zone.

•The “No Hands Zone” is defined as the entire Table plus the fixed portion of the Base on the right and left side of the Table and portions of the Fence within this boundary. This zone is labeled by “No Hands” symbols placed on the fixed Base.

•Be aware of the path of the sawblade. Make a dry run with the saw OFF by conducting a simulated cutting cycle, and observe the projected path of the sawblade. Keep hands out of the path of sawblade.

DRY RUN—It is important to know where the blade will intersect with the workpiece during cutting operations. Always perform the simulated cutting sequence with the power tool switched OFF to gain an understanding of the projected path of the sawblade. Mentally note where the path of sawblade will fall and set up your work to keep your hands and arms out of the path of the spinning blade. Adjust your clamps and fences so that the smooth lower guard and cutting action is not interfered with during cutting operation.

•Hold workpiece firmly against table and fence to prevent movement.

•Keep hands in position until trigger has been released and blade has stopped completely.

•Keep feet firmly on the floor and maintain proper balance.

•Follow the miter arm when mitering left or right. Stand slightly to the side of the saw blade.

The lower guard may not automatically open under certain cutting conditions. For example, when trying to cut work-

pieces that are near the maximum cutting height capacity. Under these conditions, the workpiece can stop the lower guard movement before the downward motion of the arm could pre-open the lower guard.

If this occurs:

• Workpiece must be securely clamped. This frees a hand to raise the guard by the lip just enough to clear the workpiece (Figure 2).

•Start the saw and begin your cut.

•Once you have cleared the position where the lower guard may bind, release the guard and it will continue to operate automatically as you cut.

	Lip
Clamp	Lower
	Guard

Workpiece

Figure 2. Raising Lower Guard

20.

! WARNING

! WARNING

Workpiece Support

Long workpieces have a tendency to tip over unless clamped down and

fully supported along their entire length.

Workpiece Clamp

The included clamp easily secures a workpiece on either base side, using either of the two clamp holes behind the fence (Figure 1).

•Minimum of 1/2" of knurl must engage clamp post to be effective.

•Adjust knob if necessary to clear fence or for large differences in wood heights.

•Insert clamp into clamp post until rubber foot comes into contact with workpiece.

•Press down and screw knob to tighten clamp.

•Move the head assembly to check clearance with clamp.

•Unscrew knob to release clamp.

There may be extreme compound cuts where clamp cannot be used.

Support workpiece with hand outside No Hands Zone. Do not try to cut short pieces that cannot be clamped and cause your hand to be in the No Hands Zone.

Figure 1. Workpiece Clamp

Workpiece

Clamp

Long workpiece support

Note: Long pieces need extra support.

Sliding Base Extensions – These extensions provide extra workpiece support and are especially useful when cutting long workpieces. To reposition the extensions, simply unlock the Base Extension Clamping Levers, reposition the extensions, and relock the levers (Figure 2).

Sliding

Base

Extensions

Clamp

Levers

Figure 2. Sliding Base Extensions

Horizontal Clamp – The optional MS1221 Horizontal Clamp can be mounted on either side of the tool and holds the workpiece firmly against the fence.

Conventional Clamps – and other hold down devices can be used to hold the workpiece firmly against the table and the fence.

21.

Basic Saw Operations (continued)

Auxiliary Fence

Certain types of molding need a fence face extension because of the size and position of the workpiece. Holes are provided in the fence to attach an auxiliary fence. The auxiliary fence is used with the saw in the 0° bevel position only.

1.Place a piece of wood against the miter saw fence. (Wood can have a maximum height of 4-1/2". Check that auxiliary fence assembly does not interfere with head assembly.)

For splinter-free cuts of molding, attach a one piece wood auxiliary fence and then cut openings with miter saw.

2.Mark the locations of the support holes on the wood from the back side of the fence.

3.Drill and countersink the holes on the front of the support board.

4.Attach (each) auxiliary fence using two (2) 3/16" flat head machine screws. With 3/4" auxiliary fence use 1-1/2" long screws. Secure behind metal fence with washer and machine nuts.

Alternate: With 3/4" auxiliary fence, use 1/4" round head wood screws (3/4" long). Drill four (4) pilot holes (smaller than 1/4”) through the auxiliary fence and run screws through rear of metal fence.

5.Make a full depth cut to create the blade slot. Check for interference between the auxiliary fence and the lower blade guard. Make adjustments as necessary.

	! WARNING	Check for interference from any
		components.

Flat Head

Machine

Screws

Auxiliary

Fence

Blade Slot

Figure: Auxiliary Fence

22.

Switch Activation

For safety, the switch lever is designed to prevent accidental starts. To operate safety switch, press the switch “Lock-OFF” button with either thumb to disengage the lock, then pull the power switch lever and release the switch “Lock-OFF” release button. When the power switch lever is released, the switch “LockOFF” button will engage the safety switch automatically, and the lever will no longer operate until either “Lock-Off” button is pressed again.

NOTE: Switch lever can accommodate a padlock with a long shackle of up to 1/4" in diameter (not supplied) to prevent unauthorized use.

Power

Switch Lever

Switch “Lock-Off”

Release Button

Figure: Switch Activation

Miter Detent Override

The miter detent override feature allows the detent action to be locked out, allowing for micro adjustments at any miter angle. When the desired miter angle is to close to a standard mitering angle that has a detent slot, this feature prevents the wedge on the miter arm from slipping into the detent slot on the base.

To Engage:

1.Lift and hold the miter detent lever.

2.Push the detent override clip forward and latch in place over edge. Release miter detent lever.

3.Move miter arm to any position on the miter scale.

4.Lock the miter lock knob to retain miter position.

To Disengage:

Loosen miter lock knob and lift the miter detent lever to release the detent override clip. The clip should automatically disengage.

Detent

Override

Clip

Miter	Miter Gauge
Detent
Lever	Lock Knob

Figure: Detent Override

23.

Basic Saw Operations (continued)

Sliding Base and Fence Extensions

So as to provide sufficient (mini- ! WARNING mum 6”) spacing from hand to saw

blade, extend the sliding fences and base extensions when making extreme bevel, miter or compound cuts.

The base extensions can also be used to provide extra support for long workpieces.

Sliding Base:

1.Loosen the base extension clamping levers.

2.Extend sliding base extensions to the desired position.

3.Press the levers down to clamp the extensions into place.

Base Extensions:

•If desired, the height of the top of the base extensions can be adjusted slightly by increasing the distance between the extension and the main part of the base.

•If the clamping force of the Base Extension Clamping Levers needs to be adjusted, simply pull the red tab outward and rotate it toward the center of the saw. Let the red tab spring back into a new groove. When the red tabs are rotated down to clamp the rods, they will grip the rods with greater strength.

Sliding Fence:

1.Loosen the fence locking knobs (behind fence).

2.Slide fence to proper position.

3.Tighten knobs to lock fence into place.

To Temporarily Remove Sliding Fence:

Some extreme compound angles make it necessary to remove one of the sliding fences.

1.Unscrew fence knob until at least 1/2” of thread shows.

2.Slide fence to its furthest inward position.

3.Lift fence to remove.

4.Tighten knob

After the cut is complete, reinstall the sliding fence.

To reinstall the sliding fence, reverse this procedure.

! CAUTION During transportation, sliding base extensions and fences should

always be secured in the fully closed position.

See page 21 for information about other types of workpiece support.

Sliding

Fence

Base

Extension

Base Extension

Clamping lever

Figure: Sliding Fences and Base Extensions

24.

Saw Operations

Miter Cut

•A “miter cut” is a cross-cut made with the blade vertical (non-tilted) at a horizontal angle relative to the fence.

•A miter cut is made at 0° bevel and any miter angle in the range from 52° left to 60° right.

•The miter scale shows the angle of the blade relative to the fence angle is cast-in on the table for easy reading.

•Positive detents have been provided for fast and

accurate mitering at 0°, 15°,	22.5°, 31.6°
and 45° left and right and 60° right.

•The crown molding detents (left and right) are at 31.6° (See Cutting Crown Molding for more information page 29).

•For precision settings at angles next to the detents, use the detent override to lock out the detent. This prevents the wedge on the detent lever from slipping back into the detent.

•The kerf inserts should be as close to the blade as possible without touching the blade (see Kerf Inserts for adjustment procedures).

Follow these instructions for making your miter cut:

1.Loosen miter lock knob. Lift miter detent lever and move the saw to the desired angle, using either the detents or the miter scale. Tighten miter lock knob.

2.Extend the base extensions and fence on the side on which the cut will be made. (See Sliding Fences and Base Extensions on page 24).

3.Properly position workpiece. Make sure workpiece is clamped firmly against the table or the fence.

Use clamping position that does not ! WARNING interfere with operation. Before

switching on, lower head assembly to make sure clamp clears guard and head assembly.

4.Wait until blade comes to a complete stop before returning head assembly to the raised position and/or removing workpiece.

Workpiece

Clamp

Workpiece	Miter
	Scale	Detents	Miter Lock
			Knob

Figure: Miter Cut

25.

Saw Operations (continued)

Bevel Cut

•A “bevel cut” is a cross-cut made with the blade perpendicular to the fence but tilted away from the vertical position.

•A bevel cut is made at 0° miter and any bevel angle in the range up to 47°.

•There are factory set bevel stops at 0° and 45° on both the left and right. (See Adjustment section if adjustments are required.)

•The front-positioned bevel range selector knob provides three bevel range choices.

•There are also positive crown molding bevel stops at 33.9° on both the left and right. Disengage this stop unless using the 33.9° angle (See Cutting Crown Molding for details.)

•The front-positioned bevel lock lever locks the head assembly at the desired bevel angle.

Bevel Range Selection

Choose the desired bevel range using the bevel range selector knob (Figure 1).

45°-0 Left

To operate in Bevel Range - 45° Left to 0°

(This left bevel range is the default setting)

a.Extend left sliding fence to clear saw assembly and re-lock (Figure 2).

b.Lift bevel lock lever to release bevel lock (Fig. 1).

c.Grasp the front carry handle with right hand and tilt saw head to angle desired (Figure 2).

d.Push down bevel lock lever until you feel the lever snap into the locked position.

0-45° Right

To operate in Bevel Range 0° to 45° Right:

a.Extend right sliding fence to clear saw assembly and re-lock (Figure 2).

b.Lift bevel lock lever to release bevel lock (Fig. 1).

c.Standing on right side of saw, grasp the front carring handle with right hand and tilt saw head slightly to the left while rotating the bevel range selector knob with left hand to “0-45° Right” (Figure 2).

d.Tilt saw head to desired right bevel angle, up to the 45° stop.

Bevel

Lock

Level

Bevel

Range

Selector

Knob

Figure 1.

Front

Carry

Handle

Sliding

Fence

Figure 2.

e.Push down bevel lock lever until you feel the lever snap into the locked position.

NOTE: When the saw assembly is tilted back left past 0°, the bevel control knob will snap back to the default bevel range 1. This is designed to regain the pre-set bevel stop at the important 0° position.

Max

Range

To operate in Bevel Range 47° Left to 47° Right:

This full capacity bevel range setting overrides all preset stops and allows for cutting at bevel angles beyond the normal 45° on either side.

a.Move left or right sliding fence to clear saw assembly and re-lock (Figure 2).

b.Lift bevel lock lever to release bevel lock (Fig. 1).

c.Standing on right side of saw, grasp the front carring handle with right hand and tilt saw head

26.

slightly to the left while rotating the bevel range	2. Properly position workpiece. Make sure work piece
selector knob with left hand to “Max Range”	is clamped firmly against the table and the fence.
(Figure 2).	NOTE: Use clamping position that does not inter-
d. Tilt saw head to any angle from 47° left to 47°	fere with operation.
right.	3. Before turning the saw on, practice the cutting
e. Push down bevel lock lever until you feel the lever	action to make sure the fence clears the guards
snap into the locked position.	and adjust as necessary.
	4. Wait until blade comes to a complete stop before
Follow these instructions for making	returning head assembly to the raised position
your bevel cut:	and/or removing workpiece.
1. Extend the base extensions on the side on which
the cut will be made. (See Sliding Fence and Base
Extension on page 24).

Compound Cuts

•A “compound cut” is a cut made with the blade set to both an angle relative to the fence (miter angle) and an angle relative to the base (bevel angle).

•Because it may take several tries to obtain the desired compound angle, perform test cuts on scrap material before making your cut.

Follow these instructions for making your compound cut:

1.Extend the base extensions and fences on the side on which the cut will be made. (See Sliding Fences and Base Extensions on page 24.)

2.Properly position workpiece. Make sure workpiece is clamped firmly against the table or the fence.

Use clamping position that does not ! WARNING interfere with operation. Before

switching on, lower head assembly to make sure clamp clears guard and head assembly.

3.Set miter and bevel angles according to the instructions on pages 25 and 26 for miter and bevel cuts.

4.Wait until blade comes to a complete stop before returning head assembly to the raised position and/or removing workpiece.

Workpiece

Clamp Bevel Angle

Scale

Workpiece

Miter

Angle

Figure: Compound Cut

27.

Saw Operations (continued)

Flip-Up Crown Stops /

Length Stop

This tool comes equipped with a left and a right flipup crown molding stop. The stops can be stored behind the fence for normal cutting operations, used as a length stop, and can be easily flipped into position to be used as a crown molding stop.

Instructions for installing the crown molding stops:

1.Locate the included 2 (two) flip up crown molding/length stops (one left, and one right), 2 (two) knobs, and 2 (two) flat washers.

2.Hold one flip up crown molding/length stop to the side of the sliding base and mount by screwing one knob with washer through the slot of the stop and into the rear mounting hole as shown in figure 1.

NOTE: there are 2 (two) holes on the rib of the sliding base. Use rear hole for cutting most sizes of crown moldings. Use front hole ONLY for large crown moldings over 5-1/4” in size.

For Use As Crown Stop:

With the flip up crown molding stops now assembled to the tool, simply loosen the knob enough for the stops to move, position properly for use, and tighten.

For Storage On The Tool:

To move the stops out of the way for normal cutting operations, simply loosen the knob, slide the flip up crown molding/length stop all the way forward towards the front of the tool, flip it over the fence, slide the flip up crown molding/length stop into its resting position, and re-tighten the knob. (Figure 2). NOTE: for normal cutting operations without the crown stop, or length stop being used, keep the stock stop tab behind the stationary fence.

For Use As A Length Stop:

If the flip up crown molding/length stop is in the rear (storage) position, you can set the stop by simply unscrewing the knob and sliding the stop towards the front of the tool until it stops and retighten the knob (Figure 3).

! WARNING Use only one length stop. Using length stops on both sides of blade,

could trap workpiece and could cause workpiece to be thrown.

The length stop can be used when making repetitive cuts of the same length.

To set the cut length: unlock the base extension clamping lever, reposition the base extension and length stop, and relock the base extension clamping lever.

The maximum length that can be cut using the length stop is approximately 20”.

Crown Stop

Washer

Sliding	Front	Rear	Knob
Base	Hole	Hole

Figure 1: Crown Stop

Figure 2: Storage Position

Workpiece

Length

Stop

Figure 3: Length Stop

28.

	Cutting Base Molding	• Follow the table for helpful hints on cutting base
		molding for corners that have 90° angles.

•Base molding can be cut vertical against fence or flat on the table. The maximum size that can be vertical on the fence is 4-1/4", flat on table is 8".

BASE MOLDING CUTTING INSTRUCTIONS

LOCATION OF					Molding in Vertical Position:		Molding in Horizontal Position:
MOLDING					Back of molding is		Back of molding is flat
ON SAW					against the fence		on the table
Molding Piece Being Cut					To left of corner	To right of corner	To left of corner	To right of corner
Inside	Miter Angle				Left at 45°	Right at 45°	0°	0°
corner of wall	Bevel Angle				0°	0°	45° left	45° right

Right

Outside corner of wall

Left	Right

Position of	Bottom	Bottom	Top against	Top against
molding on Saw	against table	against table	fence	fence
Finished	Keep left	Keep right	Keep left	Keep right
side	side of cut	side of cut	side of cut	side of cut
Miter Angle	Right at 45°	Left at 45°	0°	0°
Bevel Angle	0°	0°	45° right	45° left
Position of	Bottom	Bottom	Top against	Top against
molding on Saw	against table	against table	fence	fence
Finished	Keep left	Keep right	Keep left	Keep right
side	side of cut	side of cut	side of cut	side of cut

	Cutting Crown Molding	angle”.) NOTE: These		detents	cannot be
		used with 45° crown molding.
	• Crown molding cuts must be positioned properly to
		• See also pages 25 and 26 for miter and bevel angle
	fit exactly.
		charts for cutting crown moldings			that	have
	• There are two ways to cut crown molding: flat on
		38° and 45° spring angles (and the material is
	table or angled to table and fence.	laid flat on the miter saw base).
	• Crown molding’s “spring angle” is the angle	• Even though these angles are standards, most
	between the back of the molding and the bottom flat	rooms do not have angles of exactly 90°, therefore,
	surface that fits against the wall.	you will often need to fine tune your settings.
	• This miter saw has special miter detents at	The	optional Bosch	DWM40L	MiterFinder
	31.6° and bevel detents at 33.9°. These	Digital	Anglefinder/Protractor measures			spring
	detents allow you to easily position most crown	angles and corner angles, then automatically deter-
	moldings flat on the table and make precise cuts	mines the exact miter and bevel settings
	for 90° corners. (These detents are only for use	necessary to make each crown molding cut fit
	with crown moldings that have a 38° “spring	perfectly.
		29.

Saw Operations (continued)

Crown Molding Laying Flat on Table

Notes: Position workpiece with its back flat on the saw table.

Always place top edge of molding against fence (Decorative edge is at the bottom of crown molding.)

•"Spring angle" refers to angle between wall and crown molding.

1.For 90° corner, set the bevel and miter angles using Charts below. Tighten the miter lock knob and the bevel lock lever.

2.Position molding on saw table. Clamp workpiece in place using the clamp.

Use clamping position that does not ! WARNING interfere with operation. Before

switching on, lower head assembly to make sure clamp clears guard and head assembly.

3.Wait until blade comes to a complete stop before returning head assembly to the raised position and/or removing workpiece.

NOTE: ALWAYS TAKE A TEST CUT USING SCRAP TO CONFIRM CORRECT ANGLES.

Workpiece

Clamp

33.9° Bevel

Crown

Molding 31.6°

Miter

Figure: Crown Molding Laying Flat on Table

Miter and Bevel Settings for Standard Crown Molding Cuts

(When Crown Molding is Lying Flat on Table) Assumptions: Molding is milled consistently. Corner is exactly 90°.

Molding Spring Angle is 38 degrees

	Miter	Bevel
	(Table)	(Tilt)
	Setting	Setting
Inside Corner
Left end (A)	(31.6) Right	(33.9) Left
Use the left end of the cut
Right end (B)	(31.6) Left	(33.9) Right
Use the right end of the cut
Outside Corner
Left end (C)	(31.6) Left	(33.9) Right
Use the left end of the cut
Right end (D)	(31.6) Right	(33.9) Left
Use the right end of the cut

Molding Spring Angle is 45 degrees

	Miter	Bevel
	(Table)	(Tilt)
	Setting	Setting
Inside Corner
Left end (A)	(35.3) Right	(30.0) Left
Use the left end of the cut
Right end (B)	(35.3) Left	(30.0) Right
Use the right end of the cut
Outside Corner
Left end (C)	(35.3) Left	(30.0) Right
Use the left end of the cut
Right end (D)	(35.3) Right	(30.0) Left
Use the right end of the cut

30.