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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See page 2 Ver página 38 Voir page 74
2.
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
Table of Contents
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.
3.
Safety
“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.
“SAVE THESE INSTRUCTIONS”
WARNING
!
4.
“SAVE THESE INSTRUCTIONS”
● 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 mea-
sures 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 speci-
fied 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.)
Safety
“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.
WARNING
!
“SAVE THESE INSTRUCTIONS”
5.
● 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 work-
pieces, 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 con-
tacting 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 saw-
ing 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.
Safety
“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.
WARNING
!
6.
● Do not allow familiarity gained from frequent
use of your miter saw to become commonplace. Always remember that a careless frac-
tion 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.
Safety
“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.
“SAVE THESE INSTRUCTIONS”
WARNING
!
WARNING
!
WARNING
!
DESIGNATED DANGER ZONE.
AVOID POSITIONING HANDS,
FINGERS OR ARMS IN THE
AREA DESIGNATED BY THIS
SYMBOL.
7.
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
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.
Double Insulated Tools
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.
Extension Cords
● 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.
Safety
“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.
“SAVE THESE INSTRUCTIONS”
WARNING
!
WARNING
!
WARNING
!
8.
Getting To Know Your Miter Saw
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.
WARNING
!
9.
2
3
5
4
6
7
8
9
10
11
1213141516
18
1
3
3
.9
45
17
19
20
21
22
24
23
25
26
27
28
29
30
32
33
34
36
37
38
35
31
39
Tools for Assembly & Alignment
1
2
3
10mm/17mm Combination Open End Wrench
(supplied)
Combination Square (not included)
3mm Hex “L” Wrench
(supplied)
Multi-Purpose Tool with Bit (4mm/Philips #2)
(supplied, stored on the right rear base)
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.
10.
Before moving the saw: Lock the
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
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.
WARNING
!
WARNING
!
Unpacking & Checking Contents
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.
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.
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
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.
Assembly
11.
Installation And Removal Of The Blade
WARNING
!
WARNING
!
Outer Washer
Inner
Washer
Sawblade
Shoulder
Blade Bolt
(Left Hand Thread)
Inner
Washer
Arbor
Shaft
Upper
Guard
Lower Guard
Outer
Washer
Cover Plate
Front & Rear
Cover Plate Screws
Blade Bolt
Figure 1. Blade Removal
Figure 2. Blade Hardware
Figure 3. Blade Installation
WARNING
!
WARNING
!
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.
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.
Assembly (continued)
12.
Miter Gauge
Lock Knob
Shaft
Figure: Miter Lock Knob
WARNING
!
B
EVEL
S
TO
PS
:
R
IGHT
45
º
0º
Dust
Elbow
Dust Bag
Dust
Port
Figure: Dust Elbow and Dust Bag
13.
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.
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).
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.
Blade
Combination
Square
WARNING
!
Bevel Lock
Lever
Figure 1. Blade Square to Table
D
A
B
E
Figure 2a. Calibrating Blade at
0 degrees (90° to the table)
Figure 2b. Calibrating Blade at
0 degrees (90° to the table)
3mm “L”
Wrench
in
0° Access
Hole
Bevel
Pointer
14.
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.
Adjustments (continued)
Figure 1. Right 45° Bevel Stop
Figure 2. Right 45° Bevel Adjustment
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
Combination
Square
WARNING
!
15.
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.
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 posi-
tion 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.
Table
Blade
Combination Square
Bevel Lock
Lever
Figure 1. Left 45° Bevel Stop
F
E
Figure 2. Left 45° Bevel Adjustment
16.
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 assem-
bly 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 con-
tact with the square.
e. Tighten the four (4) hex bolts.
f. Re-attach sliding fence.
Fence
Blade
Combination
Square
Hex
Bolts
Hex
Bolts
Fence
Knob
Fence
Knob
WARNING
!
Figure 1. Blade Square to Fence
Figure 2. Fence Adjustment
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.
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 pur-
pose 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.
Figure: Kerf Insert
17.
Screw
Access
Hole
Miter
Scale
Indicator
Kerf
Insert
Screws
Phillips
Screwdriver
18.
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.
Transporting, Placement & Mounting
Mounting Applications
To avoid injury always observe the
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.
WARNING
!
CAUTION
!
Figure: Workbench Mounting
19.
Mounting Applications
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.
Adjusting the Four Position Switch Handle
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
Handle
Lock
Clamp
Handle
Rotation
Release
Lever
Figure: Portable Mounting Using Clamps
Figure: Setting Main Handle Position
a.
b.
c.
d.
20.
Position your body and hands properly to make cutting easier and
safer. Observe the following instructions (Figure 1).
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 automati-
cally open under certain cutting
conditions. For example, when trying to cut workpieces 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.
Figure 2. Raising Lower Guard
Basic Saw Operations
Body and Hand Position
WARNING
!
WARNING
!
Lip
Clamp
Lower
Guard
Workpiece
Correct Incorrect Use
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
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.
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).
Figure 2. Sliding Base Extensions
21.
Workpiece Support
WARNING
!
WARNING
!
Workpiece
Clamp
Sliding
Base
Extensions
Clamp
Levers
22.
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.
Check for interference from any
components.
Figure: Auxiliary Fence
WARNING
!
Auxiliary
Fence
Blade Slot
Flat Head
Machine
Screws
23.
Figure: Detent Override
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
Detent
Lever
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
Miter Gauge
Lock Knob
Figure: Switch Activation
24.
So as to provide sufficient (mini-
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 exten-
sions 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 Base and Fence Extensions
WARNING
!
Sliding
Fence
Base
Extension
Base Extension
Clamping lever
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.
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.
Figure: Sliding Fences and Base Extensions
CAUTION
!
Basic Saw Operations (continued)
25.
Miter Cut
• A “miter cut” is a cross-cut made with the blade ver-
tical (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
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.
WARNING
!
Workpiece
Miter Lock
Knob
Miter
Scale
Detents
Workpiece
Clamp
Figure: Miter Cut
Saw Operations
26.
Bevel Cut
• A “bevel cut” is a cross-cut made with the blade per-
pendicular 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).
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.
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 car-
ring 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.
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.
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 assem-
bly 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
Saw Operations (continued)
Bevel
Range
Selector
Knob
Sliding
Fence
Front
Carry
Handle
Figure 1.
Figure 2.
Bevel
Lock
Level
45°-0
Left
0-45°
Right
Max
Range
27.
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
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.
WARNING
!
Miter
Angle
Workpiece
Workpiece
Clamp
Bevel Angle
Scale
slightly to the left while rotating the bevel range
selector knob with left hand to “Max Range”
(Figure 2).
d. Tilt saw head to any angle from 47° left to 47°
right.
e. Push down bevel lock lever until you feel the lever
snap into the locked position.
Follow these instructions for making
your bevel cut:
1. Extend the base extensions on the side on which
the cut will be made. (See Sliding Fence and Base
Extension on page 24).
2. Properly position workpiece. Make sure work piece
is clamped firmly against the table and the fence.
NOTE: Use clamping position that does not interfere with operation.
3. Before turning the saw on, practice the cutting
action to make sure the fence clears the guards
and adjust as necessary.
4. Wait until blade comes to a complete stop before
returning head assembly to the raised position
and/or removing workpiece.
Figure: Compound Cut
28.
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).
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”.
Saw Operations (continued)
Knob
Sliding
Base
Washer
Crown Stop
Length
Stop
Workpiece
WARNING
!
Figure 3: Length Stop
Figure 2: Storage Position
Figure 1: Crown Stop
Rear
Hole
Front
Hole
29.
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
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
Outside Miter Angle Right at 45° Left at 45° 0° 0°
corner of wall 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
Left
Right
Left
Right
Cutting Base Molding
• 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".
• Follow the table for helpful hints on cutting base
molding for corners that have 90° angles.
Cutting Crown Molding
• Crown molding cuts must be positioned properly to
fit exactly.
• There are two ways to cut crown molding: flat on
table or angled to table and fence.
• Crown molding’s “spring angle” is the angle
between the back of the molding and the bottom flat
surface that fits against the wall.
• This miter saw has special miter detents at
31.6° and bevel detents at 33.9°. These
detents allow you to easily position most crown
moldings flat on the table and make precise cuts
for 90° corners. (These detents are only for use
with crown moldings that have a 38° “spring
angle”.) NOTE: These detents cannot be
used with 45° crown molding.
• See also pages 25 and 26 for miter and bevel angle
charts for cutting crown moldings that have
38° and 45° spring angles (and the material is
laid flat on the miter saw base).
• Even though these angles are standards, most
rooms do not have angles of exactly 90°, therefore,
you will often need to fine tune your settings.
The optional Bosch DWM40L MiterFinder
Digital Anglefinder/Protractor measures spring
angles and corner angles, then automatically determines the exact miter and bevel settings
necessary to make each crown molding cut fit
perfectly.
30.
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
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.
Figure: Crown Molding Laying Flat on Table
Saw Operations (continued)
WARNING
!
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
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°.
Workpiece
Clamp
Crown
Molding
31.6°
Miter
33.9° Bevel
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