Bosch 4405 User Manual
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Operating/Safety Instructions
Consignes de fonctionnement/sécurité
Instrucciones de funcionamiento y seguridad
4405
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Safety
!
WARNING
“READ ALL INSTRUCTIONS” — Failur
BULLET (l) symbol listed BELOW and other safety precautions, may result in serious personal injury.
General Safety Rules
For Bench Top Tools
Work Area
l Keep work area clean and well lit. Cluttered
benches and dark areas invite accidents.
l 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.
l Keep bystanders, children and visitors away
while operating a power tool. Distractions
can cause you to lose control.
l Store idle tools out of reach of children and
other untrained persons. Tools are dangerous in the hands of untrained users.
l Do not leave tool running unattended, turn
power off. Do not leave tool until it comes to a
complete stop.
l MAKE WORKSHOP CHILDPROOF with pad
lock, master switches, or by removing starter
keys.
Electrical Safety
l 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
ds and damage to the tool.
hazar
l 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.
the need for the thr
powercord and grounded power supply.
l Avoid body contact with gr
such as pipes, radiators, ranges and refrigerators.
shock if your body is grounded.
There is an increased risk of electric
Double insulation eliminates
ee wire grounded
ounded surfaces
e to follow the SAFETY RULES identified by
l Do not expose power tools to rain or wet
conditions.
increase the risk of electric shock.
l 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.
the risk of electric shock.
l 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.
Water entering a power tool will
Damaged cords increase
Personal Safety
l 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.
l 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.
l 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.
l Remove adjusting keys or wr
ning the tool “ON”.
tur
is left attached to a r
be thrown.
l Do not overreach, keep proper footing and
balance at all times. Proper footing and balance enables better control of the tool in unexpected situations.
l 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.
otating part of the tool will
enches before
ench or a key that
A wr
“SAVE THESE INSTRUCTIONS”
2.
Safety
!
WARNING
l 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.
“READ ALL INSTRUCTIONS” — Failur
BULLET (l) symbol listed BELOW and other safety precautions, may result in serious personal injury.
Tool Use and Care
l 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.
l Do not force tool. Use the correct tool for
your application.
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.
l Do not use tool if switch does not turn it
“ON” or “OFF”. Any tool that cannot be controlled with the switch is dangerous.
l 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.
l 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.
l Inspect guards before using a tool. Keep
ds in place. Check moving parts for
guar
binding or any other condition that may
affect the normal operation or safety features of the tool. If damaged, have tool serviced befor
are caused by poorly maintained tools.
l Do not alter or misuse tool. Any alteration or
modification is a misuse and may result in serious personal injury
l 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.
e using the tool.
The correct tool will do the
Many accidents
.
e to follow the SAFETY RULES identified by
Service
l 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.
l 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
l 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.
l 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.
l 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 danger
l Always disconnect the power cord from the
power sour
ments or attaching any accessories. Y
may unintentionally start the saw, leading to
serious personal injury.
l Miter saws are intended to cut wood or
woodlike products, they cannot be used
with abrasive cutoff wheels for cutting
ous material such as bars, r
ferr
etc. However
aluminum or other non-ferr
only saw blades specifically r
for non-ferr
materials causes excessive sparking and will
damage the lower guar
motor
does not offer 10” metal cutting blades.)
ous.
ce before making any adjust-
, if cutting materials like
ous metals, use
ous metal cutting.
d and will overload the
. (NOTE: Bosch Power T
ou
ods, studs,
ecommended
Cutting ferr
ool Company
ous
“SAVE THESE INSTRUCTIONS”
3.
Safety
!
WARNING
l Inspect your workpiece before cutting. If
“READ ALL INSTRUCTIONS” — Failur
BULLET (l) symbol listed BELOW and other safety precautions, may result in serious personal injury.
workpiece is bowed or warped, clamp it with
the outside bowed face towar
d 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.
l 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 revolv
ing blade can be thrown with high speed at
the operator.
l 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.
l 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.
l 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.
l 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 20).
Workpieces longer or wider than the miter saw
table can tip if not secur
ely supported. If the
cutoff piece or workpiece tips it can lift the
lower guar
l Do not use another person as a substitute
d or be thr
own by the spinning blade.
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.
l The cutoff piece must not be jammed
ed by any other means
against or pr
against the spinning saw blade.
essur
If confined,
i.e. using length stops, it could get wedged
against the blade and thrown violently.
l Always use a clamp or a fixture designed to
properly support r
dowel rods, or tubing.
ound material such as
Rods have a tendency
to roll while being cut, causing the blade to
“bite” and pull the work with your hand into
the blade.
e to follow the SAFETY RULES identified by
l When cutting irregularly shaped work-
pieces, plan your work so it will not slip and
pinch the blade and be tor
n 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.
l Let the blade reach full speed before con-
tacting the workpiece.
This will help avoid
thrown workpieces.
l 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 compound miter saw.
l 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.
l 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!
l There are additional safety instructions
for particular operations of the saw in the
operating section. Read the rest of the manual for safe operation.
l For slide action cutting, first PULL saw head
assembly away from the fence, until blade
clears the workpiece or to its maximum
extension if blade cannot clear the workpiece. Make certain the clamp does not
interfer
e with the guar
d and head assembly
.
Second, turn saw “ON” and lower the saw to
the table. Then PUSH saw thr
ough the workpiece. Release the switch and wait for the
blade to completely stop befor
e raising the
head assembly and removing the workpiece.
Never “pullcut” since the blade may climb the
workpiece causing KICKBACK.
l For chop action cutting, slide the head
assembly to the rear as far as it will go and
tighten slide lock knob. Then tur
n 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.
Failure to tighten the slide lock knob can cause
the blade to suddenly climb up on the top of the
workpiece and force itself toward you.
“SAVE THESE INSTRUCTIONS”
4.
Safety
!
WARNING
l Do not allow familiarity gained from frequent
use of your miter saw to become commonplace.
tion of a second is suf
injury
l 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.
!
WARNING
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.
“READ ALL INSTRUCTIONS” — Failure to follow the SAFETY RULES identified by
BULLET (l) symbol listed BELOW and other safety precautions, may result in serious personal injury.
Always remember that a careless frac-
ficient to inflict severe
.
THE WARNINGS SHOWN
BELOW CAN BE FOUND ON
!
WARNING
drilling, and other construction activities contains
chemicals known
other r
these chemicals are:
• Lead from lead-based paints,
• Crystalline silica from bricks and cement and other
• Arsenic and chromium from chemically treated
Your risk from these exposures varies, depending on
how often you do this type of work. T
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.
eproductive harm. Some examples of
masonry products, and
lumber.
Some dust created by power
sanding, sawing, grinding,
to cause cancer, birth defects or
o reduce your
DESIGNATED
DANGER ZONE.
AVOID POSITIONING
HANDS, FINGERS OR
ARMS IN THE AREA
DESIGNATED BY
THIS SYMBOL.
“SAVE THESE INSTRUCTIONS”
5.
Safety
!
WARNING
“READ ALL INSTRUCTIONS” — Failur
BULLET (l) symbol listed BELOW and other safety precautions, may result in serious personal injury.
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.
l Servicing of a tool with double insulation
requires care and knowledge of the system
and should be performed only by a qualified
service technician.
l WHEN SERVICING, USE ONLY IDENTICAL
REPLACEMENT PARTS.
l 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.
e to follow the SAFETY RULES identified by
Extension Cords
l Replace damaged cords immediately. Use of
damaged cords can shock, burn or electrocute.
l 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 name
plate 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
“SAVE THESE INSTRUCTIONS”
Table of Contents
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Safety Rules For Bench Top Tools . . . . . . . . 2
Safety Rules For Miter Saws . . . . . . . . . . . . . . . . . . 3-6
Table of Contents. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Electrical Requirements . . . . . . . . . . . . . . . . . . . . . . . . 7
Getting To Know Your Miter Saw . . . . . . . . . . . . . . . 8-9
Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tools Needed For Assembly And Alignment . . . . . . 10
Unpacking and Checking Contents . . . . . . . . . . . . . 10
Attaching Miter Lock Knob
Assembling Dust Elbow and Dust Bag . . . . . . . . . . . 11
Installation and Removal of the Blade . . . . . . . . . . . 12
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-16
Blade Square To Table (90°) . . . . . . . . . . . . . . . . . . . 13
Blade 45° To The Table . . . . . . . . . . . . . . . . . . . . . . . 14
Blade 33.9º T
Blade Square To Fence. . . . . . . . . . . . . . . . . . . . . . . 16
Miter Scale Indicator Adjustment . . . . . . . . . . . . . . . 16
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mounting Applications . . . . . . . . . . . . . . . . . . . . . . . 17
Portable Mounting Using Clamps
Stability Bar Adjustment . . . . . . . . . . . . . . . . . . . . . . 18
o The T
. . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . .
able
. . . . . . . . . . . . . . .
2-6
10-12
11
15
17-18
18
NOTE: The smaller the gauge number, the heavier
the cord.
Basic Saw Operations . . . . . . . . . . . . . . . . . . . . . .
Body and Hand Position . . . . . . . . . . . . . . . . . . . . . . 19
Workpiece Support . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Auxilliary Fence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Switch Activation. . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Detent Override . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Sliding Base/Fence Extension
Saw Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-31
Chop Cut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Slide Cut
Miter Cut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Bevel Cut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25-26
Compound Cuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Cutting Grooves (Dado Cut) . . . . . . . . . . . . . . . . . . . 27
Cutting Base Molding . . . . . . . . . . . . . . . . . . . . . . . . 28
Cutting Cr
Special Cuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Maintenance and Lubrication. . . . . . . . . . . . . . . . . . . 32
roubleshooting
T
Slide Action Adjustment . . . . . . . . . . . . . . . . . . . . . . 35
Adjusting Bevel Lock Lever T
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
own Molding
. . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . 35
ension
19-22
22-23
24
28-30
33-35
6.
Electrical Requirements
Connect this saw to a 120V, 15-amp branch cir-
1.
cuit with a 15-amp time delay fuse or cir
breaker. Using the wrong size fuse can damage
the motor.
Fuses may “blow” or circuit breakers may trip
2.
equently if motor is overloaded. Overloading
fr
can occur if you feed the blade into the workpiece too rapidly, start and stop too often in a
short time, or use the wrong blade for
the application.
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
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.
cuit
!
WARNING
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.
!
WARNING
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.
When electrical power is lost due to
blown fuse or other causes, the
The brake action of this saw is not
intended as a safety feature.
7.
Getting To Know Your Miter Saw
1
4
30
2
40
3
28
20
16
41
19
32
25
22
29
5
26
27
6
23
21
24
7
8
18
7
9
40
12
18
14
15
17
16
o avoid injury fr
!
WARNING
source outlet before making any adjustments.
1. Switch “Lock-OFF” Button
This button must be pressed to activate the power switch.
2. Power Switch
The power switch (used with the “Lock-OFF” button) ener
gizes the unit.
3. Switch Handle
This handle contains the switch. The blade is lowered into
the workpiece by pushing/pulling down on the handle.
Never pick up tool by switch handle.
4. Arbor Lock
Allows the user to keep the blade fr
ening or loosening arbor scr
or removal.
T
starting, remove plug from power
ew during blade replacement
om accidental
otating while tight-
om r
43
34
11
13
5. Lower Blade Guar
The lower blade guard helps protect your hands from the
spinning blade. It r
Lip can be used to raise the lower guard manually, only as
recommended in this manual.
6. Blade
Use only 10" blades between 1.4 and 3.0mm thick, with
5/8" arbor hole.
-
7. Stationary Fence
Supports the workpiece. The fence has a cast in scale to
make repetitive cuts easy. The fence also has holes which
e used to secur
ar
8. Kerf Inserts
9. Miter Detent Override
Allows detent action to be locked out allowing for fine
adjustments to any miter angle.
d/Lower Guar
etracts as the blade is lower
e an auxiliary fence if desir
d Lip
8.
10
ed. Guard
ed.
Getting To Know Your Miter Saw
10. Miter Lock Knob
The miter lock knob locks the miter saw table at any
desired miter angle.
11. Miter Detent Trigger
The trigger releases the table from the detent.
12. Miter Scale/Miter Angle Indicator
Scale is cast in on the base of the saw. Indicator is fastened to the table.
13. Miter Detents
e are ten (10) miter detents for fast and accurate miter
Ther
cuts of common miter angles.
14. 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.
15. Base
Provides working surface to support workpiece.
16. Tool Mounting Pads
17. Base Extension Clamping Levers
Locks Base Extensions into place. One for each extension.
18. Extension Rods
Add support for long workpieces.
19. Sliding Fence
This provides extra support and clamping area for compound miter cuts.
20. Sliding Fence Clamping Lever
Locks the Sliding Fence in place.
21. Chip Deflector with Dust Flap
This protects against large chips from entering the upper
guard.
22. Dust Chute Elbow
The dust chute elbow rotates 360° and can accommodate
the dust bag or a vacuum hose hookup.
23. 0° Bevel Stop
Adjustable stop for a quick and accurate 0° bevel index.
24. 33.9º Bevel Stop
Adjustable stop for a quick and accurate 33.9° bevel index.
25. 45° Bevel Stop
Adjustable stop for a quick and accurate 45
26. Slide Rail Lock Knob
The slide rail lock knob locks the slide rails when you are
not making slide cuts and when you are transporting the
.
saw
27. Slide Rails
Guide the head assembly when making slide cuts.
28. Workpiece Clamp
Provides fast clamping of workpiece.
29. Lower Guard Actuation Link
Allows for smooth movement of the lower guard.
30. Upper Blade Guard
Covers upper portion of the blade.
31. Blade Wrench
Used for tightening/loosening blade and adjusting fence
and glide blocks. Blade wrench is stored in rear of saw.
32. Power Cord
Supplies power to motor. Has molded cord retainer for storage.
° bevel index.
2
38
37
36
42
33
32
39
33
16
35
31
16
33. Workpiece Clamp Positions
There are three (3) positions behind the fence for the workpiece clamp.
34. Bevel Lock Lever
The bevel lock handle locks the head assembly at a desired
bevel angle.
35. Bevel Scale
Indicator used to set bevel angles.
36. Head Assembly Lock Pin
Saw is equipped with a lock pin used to lock the head
assembly in the lower position. Should be locked in the
lower position during transportation.
37. Depth Stop
Allows you to adjust the depth of the blade for cutting
grooves in the workpiece.
38. Brush Caps
These caps keep the motor brushes in position and provide
easy access for inspecting and replacing brushes.
39. Sliding Fence Cover Plate
Rotate cover plate to remove fence.
40. Carry Handles
own Stop Bosses
41. Cr
Allow use of Bosch crown stops.
42. Cord Wrap
ovides location to stor
Pr
43. Stability Bar
Provides support for the end of the table.
44. Pivot Bolt
Tighten/Loosen to adjust bevel tension.
45. Bevel Lock Nut
Adjusts bevel lock clamp force.
44 45
e power cor
d.
9.
Assembly
Tools Needed For Assembly And Alignment
Phillips Screwdriver
Combination Square
Should be no Gap or Overlap
when Square is Flipped Over in
Dotted Position
Disconnect plug from power source before performing any assembly, adjustment or repair to avoid possible
injury.
Blade Wrench (supplied), hex on
other side of phillips.
Combination Square Must be True
Draw Light
Line on Board
Along this Edge
Straight Edge of
Board 3/4" Thick
This Edge Must be
Perfectly Straight
Unpacking And Checking Contents
Model 4405 Slide Compound Miter Saw is shipped
complete in one box.
1. Separate all parts from packing materials and
check each one with the “Table of Loose Parts” to
make sure all items are accounted for before discarding any packing material.
2. Table of Loose Parts: (See pages 8 and 9)
ew Clamp
Scr
Dust Elbow/Dust Bag
Miter Lock Knob
Call 1-877-BOSCH99; if you need assistance.
!
WARNING
switch on until the missing parts are obtained and
are installed correctly. Call 1-877-BOSCH99 to
obtain missing parts.
!
WARNING
Lock bevel lock handle. Pull the head assembly
completely toward you and tighten the slide rail lock
knob. Lock head assembly in the down position.
Never carry the tool by the slide rails, this may
cause blade misalignment.
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.
If any parts are missing, do not
plug in power cord or turn the
Before moving the saw: Lock the
miter lock knob in 45° position.
10.
Assembly
Attaching Miter Lock Knob
Locate the miter lock knob fr
parts and thread shaft into miter detent assembly as
shown in Figur
e 4.
om among the loose
Assembling Dust Elbow And Dust Bag
1. Push the dust elbow onto the dust nozzle.
Rotate elbow to the desired position. (Figure 5).
Dust
Bag
Dust
Elbow
Dust
Nozzle
Shaft
Figure 4: Miter Lock Knob
2. The dust bag attaches to the dust chute elbow
and is used to collect sawdust. The dust elbow
can also be attached to a standard 2" vacuum tube for dust collection.
3. Position dust elbow/bag so that it does not
interfere with the tool during the cutting operation
for all miter/bevel settings. Make sure dust bag
does not interfere with the slide rails during slide
cutting.
4. 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 extr
disposed dust, materials in fine particle form may
be explosive. Do not throw sawdust on an open
fire. Over time, spontaneous combustion can
result from mixing oil or water with dust
particles.
Miter Gauge
Lock Knob
emely careful of
Figure 5. Dust Bag and Elbow
!
WARNING
lead based, or any other materials that may contain
carcinogens, use special precautions. A suitable respirator must be wor
work ar
sheeting and persons not protected should be kept
out until work areas are thoroughly cleaned.
ea. W
When sawing chemically pressure
treated lumber, paint that may be
n by all personnel entering the
eas should be sealed by plastic
ork ar
11.
Assembly
Installation And Removal Of The Blade
!
WARNING
adjustment or repair to avoid possible injury.
1. Loosen rear cover plate screw one full turn. Do
not completely remove screw.
Loosen front cover plate screw (approximately three full
2.
turns) until it clears the tab on the cover plate; but do
not completely remove screw. Rotate coverplate
counter-clockwise, exposing arbor bolt blade area.
3. Rotate the guard by hand to clear the blade. Let go of
guard. Plastic will be held out of way by front screw.
4. Press and hold the arbor lock. The blade may
need to be rotated for the arbor lock to catch.
Use the blade wrench to remove the blade bolt
by turning wrench clockwise. NOTE: The blade
bolt has a left hand thread.
Disconnect plug from power source
before performing any assembly,
To install the 10" blade, fit blade between the
6.
chip deflectors and onto arbor shaft (Figure 3).
NOTE: Make sure the rotation arrow on the
blade matches the clockwise rotation arrow on
the lower guard.
Lower Guar
Turn Bolt This
Way to Loosen
Chip
Deflector
Figure 1. Blade Removal
5. Remove the blade bolt, arbor washer, outer
washer and the blade. Inner washer does not
need to be r
Arbor Washer
Blade Bolt
(Left Hand Thread)
emoved (Figur
Outer Washer Inner Washer
Sawblade
Blade Bolt
(Hex Cap)
e 2).
d
Front Cover
Plate Screw
Outer
Washer
Inner
Washer
Arbor Shaft
Chip
Deflector
Figure 3. Blade Installation
!
WARNING
and 5/8" arbor.
7. Replace the outer washer, arbor washer, and
tighten blade bolt finger tight counter-clockwise
(see Figure 2). Press the arbor lock and tighten
blade bolt securely using blade wrench, but do
not overtighten.
8. Rotate cover plate clockwise to original position
and tighten cover plate scr
!
WARNING
interfere with and hang-up lower blade guard.
Never use saw without cover plate secur
place. Lower guard will not function properly.
Be sur
9.
turns freely.
!
WARNING
with the table insert at the 0
tions. 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
1-877-BOSCH99
at
Replace blade wr
10.
To avoid injury, do not use a blade
larger or smaller than 10" diameter
ews.
Tighten the cover plate screws.
Loose cover plate screw may
ely in
e the arbor lock is released so the blade
After installing a new blade, make
sure the blade does not interfere
° and 45° bevel posi-
.
ench in storage ar
ea on saw
.
e 2. Blade Har
Figur
dwar
e
12.
12.
Adjustments
!
WARNING
adjustment or repair to avoid possible injury.
NOTE: Your slide compound miter saw was completely adjusted at the factory. However, during shipment, slight misalignment may have occurr
the following settings and adjust if necessary prior to
using this compound miter saw.
Disconnect plug fr
before performing any assembly,
om power source
ed. Check
Blade Square (90°)
To Table
90° Blade Alignment Check
1. Rotate table to 0° position and lock in place.
Make sure head assembly is pushed back fully
2.
against stop and slide rail lock knob is tightened.
3. Lower head assembly. Lock in place.
4. Use a combination square to check blade squareness to table. Place the combination square on
the table and press it against the blade. If the
blade does not contact the full length of the
square, (Figure 6) follow the alignment procedure.
0º Stop
Screw
Jam
Nut
Figure 7. Bevel 0° Stop Screw and Jam Nut
7. Adjust bevel indicator. Loosen screw and
align indicator to the 0° mark. Tighten screw
(Figure 8).
Combination
Square
Table
90° Blade Alignment Adjustment
1. Loosen bevel lock handle.
2. Move the head off of the 0º stop.
3. Lower 0° stop screw and jam nut with 12mm
4. Move the saw back to 0º stop.
5. Push square against blade (fig. 6).
6. Adjust 0° bevel stop screw with 12mm or
Blade
Figure 6. Blade Square to Table
or adjustable wr
adjustable wr
contact with the full length of the square.
Tighten jam nut (Figure 7).
ench.
ench until the blade makes
Figure 8. Bevel Indicator
Adjust
to 0º
Bevel
Indicator
ew
Scr
13.
Adjustments
Blade 45° To Table
45° Blade Alignment Check
1. Rotate table to 0° position and lock in place.
2. Make sure head assembly is pushed back
fully against stop and slide rail lock knob
is tightened.
3. Lower head assembly. Lock in place.
4. Make sure the 33.9º bevel stop screw jam
nut is in the passive position, out of line with
the 90º and 45º bevel stop screw jam nuts.
5. Loosen bevel lock handle and tilt the head
assembly to 45° bevel. Check the 45° bevel
stop. The bevel indicator should be on the
45° mark, the 45° bevel stop should be in full
contact with the 45° bevel stop screw. Place
the combination square on the table and
press it against the blade. The blade should
contact the full length of the combination
square (Figure 9).
6. If the blade is not 45° to the table, adjust
45°bevel stop.
45° Blade Alignment Adjustment
1. Lower the 45° bevel stop screw jam nut using
12mm or adjustable wrench (Figure 10).
Combination
Square
Figure 9. Blade 45° To The Table
45º/33.9º
Stop
45º Stop
Screw
Blade
Table
2. Loosen bevel lock handle.
Lower the saw onto the 45º stop.
3.
4. Push combination square against the blade.
5. Adjust the 45º bevel stop until the blade
makes contact with the full length of the
square. Tighten 45° jam nut (Figure 10).
6. Check that bevel indicator is pointing to the
45° mark on the bevel scale (see Figure 10).
If bevel indicator is not aligned with the 45°
mark, first recheck the blade squareness to
the table and 0° bevel indicator alignment.
Then, repeat the 45° blade alignment and
make appropriate adjustments.
14.
Jam
Nut
e 10. Bevel 45° Stop Screw and Jam Nut
Figur
Adjustments
Blade 33.9° To Table
33.9° Blade Alignment Check
NOTE: You must check and align 45º and 90º settings first before doing 33.9º (See pages 13 and 14).
1. Rotate table to 0° position and lock in place.
2. Make sure head assembly is pushed back
fully against stop and slide rail lock knob
is tightened.
3. Lower head assembly. Lock in place.
4. Make sure the 33.9º bevel stop screw jam
nut is in the active position, in-line with the
90º and 45º bevel stop screw jam nuts.
5. Loosen bevel lock handle and tilt the head
assembly to 33.9° bevel. Check the 33.9°
bevel stop. The bevel indicator should be on
the 33.9° mark.
Figure 11. Blade 33.9° To The Table
6. If the blade is not 33.9° with the table, adjust
33.9°bevel stop.
33.9° Blade Alignment Adjustment
1. Lower the 33.9° bevel stop screw jam nut
using 12mm or adjustable wrench (Figure 12).
2. Loosen bevel lock handle.
3. Lower the saw onto the 33.9º stop.
4. Adjust the 33.9º bevel stop until bevel indicator is pointing to the 33.9° mark on the bevel
scale (see Figure 12). Tighten 33.9° jam nut.
45º/33.9º
Stop
33.9º Stop
Screw
Jam Nut
Figure 12. Bevel 33.9° Stop Screw and Jam Nut
15.
Adjustments
Blade Square to Fence
Fence Alignment Check
Make sure head assembly is pulled forward near
1.
the center of the table and slide rail lock knob is
tightened (Figure 13).
2. Lower the head assembly, and lock in the
lower position.
3. Make sure table is in 0° detent and tighten miter
lock knob.
4. Place a combination square against the fence
and next to the blade as illustrated. Locate the
square properly so it does not contact the tooth
of saw blade. The saw blade should contact the
full length of the square (Figure 13).
5. If blade does not contact the square, follow the
fence alignment procedure.
Slide Rail
Lock Knob
Fence Alignment Adjustment
The head assembly should remain in lowered
1.
position.
Extend sliding fence. Use blade wrench (sup-
2.
plied) and loosen three (3) bolts behind fence
(Figure 14).
3. Adjust fence until blade and the fence has full
contact with the square.
4. Tighten hex cap screws.
Hex Cap Screws
Fence
Miter Lock
Knob
Figure 13. Blade Square to Fence
Miter Scale
Indicator Adjustment
1. Rotate table to 0° position and lock in place.
2. Raise the head assembly to the full-up position.
3.
Loosen the Phillips screw that holds the indicator in place (Figure 15).
Slide Rail Unit
Figure 14. Fence Adjustment
(Back view of table/base area)
4. Position the indicator to align with the 0° miter
mark. Tighten the screw.
16.
Indicator
Screw
0º Mark
Figure 15.
Installation
o avoid injury always observe
!
WARNING
l Unplug electric cor
saw, rotate head assembly to 45° right miter,
lock into detent, pull the head assembly com
pletely forward toward you, tighten the slide
rail lock knob and lock the head assembly in
the lowered position.
l 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 or the carry handle.
l Never carry the tool by the slide rails, this
may cause blade misalignment.
T
the following:
d. Before transporting the
Mounting Applications
l 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 wir
-
ing in electric shock or fir
l Observe the position of the saw. People
standing behind it could be injured by thrown
debris.
l Place the saw on a firm, level surface where
there is plenty of room for handling and properly supporting the workpiece.
l Bolt, screw, nail or clamp the saw to its
support surface.
!
CAUTION
attaching to support surface. This could crack foot
or damage base.
Be careful not to over drive nail
or over torque the bolt when
e connections result-
e.
Workbench
Mount the saw using either the four bolt holes (7/16") or
the four screw holes (1/4”) to the workbench (Figure
16). Check for clearance to the left and right of the saw.
Bolt Holes
ew Holes
Scr
Screw Holes
Bolt Holes
1. Each of the four mounting holes should be bolted securely using 3/8" bolts, lock washers, and
hex nuts (not included).
2. Locate and mark where the saw is to be mounted.
3. Drill four (4) 3/8" diameter holes through workbench.
Place the slide compound miter saw on the
4.
workbench aligning holes in base with holes
drilled in workbench. Install bolts, lock washers and hex nuts.
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 of the saw is noted, check your
mounting to the workbench or stand, and make necessary adjustments before operating the slide compound miter saw (see Stability Bar Adjustment on
page 18).
Figure 16. Workbench Mounting
17.
Installation
Portable Mounting Using Clamps
• If using bolts or screws is not possible, clamp the
slide compound miter saw to a workbench or
table top using clamps.
• Place a “C” clamp on each of the clamping areas
and secure (Figure 17).
Note: Use of clamps will limit use of extreme
miter angles.
Clamping Area
Clamping Area
Figure 17. Portable Mounting Using Clamps
Stability Bar Adjustment
For added support of the table during cutting, the
stability bar should be adjusted before use.
1. Loosen the knob for the stability bar.
2. Slide the stability bar up or down until it contacts the workbench.
Note: If the workbench surface is not flat, the
stability bar may require readjustment at different
miter angles.
3. Tighten the knob.
Stability Bar
Adjustment Knob
Stability Bar
Workbench
18.
0
5
10
15
20
25
30
35
40
45
50
50
45
40
35
30
BOSCH
0
5
10
15
20
25
30
35
40
45
50
50
45
40
35
30
BOSCH
0
5
10
15
20
25
30
35
40
45
50
50
45
40
35
30
BOSCH
0
5
10
15
20
25
30
35
40
45
50
50
45
40
35
30
BOSCH
Basic Saw Operations
Body and Hand Position
!
WARNING
Position your body and hands prop-
erly to make cutting easier and
safer. Observe the following instructions (Figure 18).
l Never place hands near cutting area. Keep
hands outside the “No Hands” zone.
l The “No Hands Zone” is defined as the entire
Table and fixed portions of the base and portions of the fence within this boundary. This
zone is labeled by “No Hands” symbols placed
on the Base.
l Hold workpiece (outside of the “No Hands”
zone) firmly to the fence to prevent movement
(Fig 18).
Correct Incorrect Use
!
WARNING
The lower guard may not automatically open under certain cutting
conditions.
l Typically this may occur when trying to cut work-
pieces that are near the maximum cutting height
capacity (3.5”), or when making extreme bevel
cuts at 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:
1. Workpiece must be securely clamped. This
frees a hand to raise the guard by the lip just
enough to clear the workpiece (Figure 19).
Start the saw and begin your cut.
2.
3. 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
Lower Guard
e 18. Hand Positions
Figur
l Keep hands in position until trigger has been
released and blade has stopped completely.
l Never place hands on slide rails.
l Keep feet firmly on the floor and maintain prop-
er balance.
l Follow the miter arm when mitering left or right.
Stand slightly to the side of the saw blade.
l Before making any cut, with the power off, lower
the blade to preview the blade path.
Open
Workpiece
Figure 19. Raising Lower Guard
19.
Basic Saw Operations
Workpiece Support
!
WARNING
and properly supported from underneath.
Long workpieces have a tendency
to tip over unless clamped down
Clamps
Workpiece Clamp - This clamp easily secures a
workpiece in any of three (3) clamp holes behind the
fence (Figure 20).
• Insert clamp post into clamp hole.
• Loosen wing nut and adjust arm to proper height,
and securely tighten wing nut.
• Rotate screw knob of the clamp clockwise to
tighten, counter
• Move the head assembly to check clearance
with clamp.
-clockwise to loosen.
!
WARNING
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.
Workpiece
Clamp
Clamp
Hole
Screw
Rod
There may be extreme compound
cuts where clamp cannot be used.
Clamp
Holes
Figure 20. Workpiece Clamp
Conventional Clamps and other hold down devices
can be used to hold the workpiece firmly against the
table and the fence.
20.
Basic Saw Operations
Auxiliary Fence - Certain types of molding need a
fence face extension because of the size and position of the workpiece. Dado cuts also require an auxiliary fence. 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 (Figure 21). (Wood can have a maximum
height of 3-1/2". Check that head assembly
does not interfere with auxiliary fence.)
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 the auxiliary fence using two at least (2)
1/4" flat head machine screws per side. 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
Blade Slot
Flat Head
Machine
Screws
Auxiliary
Fence
Figure 21. Auxiliary Fence
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
“Lock-OFF” button will engage the safety switch
automatically
until either “Lock-Of
NOTE: Switch lever can accommodate a padlock
with a long shackle of up to 1/4" in diameter (not
supplied) to prevent unauthorized use.
, and the lever will no longer operate
f” button is pr
essed again.
Power
Switch Lever
Switch
“Lock-Off”
Release
Buttons
Figure 22. Switch Activation
21.
Basic Saw Operations
1
Detent Override
To Engage:
1. Lift the miter detent trigger.
Push the detent override clip forward and latch
2.
in place over edge. Release miter detent trigger
(Figure 23).
3. Move miter arm to any position on the miter
scale.
4. Lock the miter lock knob to retain miter position.
To Disengage:
5. Loosen miter lock knob and lift the miter detent
trigger to release the detent override clip. The
clip should automatically disengage and the
table should lock into any desired miter detent.
Table
Clip Edge
Detent
Override Clip
Base Extensions
!
WARNING
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.
Adjusting the Extensions:
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.
If the clamping force of the Base Extension Clamping
Levers needs to be adjusted, simply pull the r
outwar
Let the red tab spring back into a new groove. When
the red tabs ar
will grip the rods with gr
d and r
So as to provide sufficient (mini-
mum 6”) spacing from hand to
ed tab
otate it towar
e rotated down to clamp the rods, they
d the center of the saw
eater for
ce.
.
Base
Extension
Miter Detent
Trigger
Figure 23. Detent Override
Figure 24: Base Extensions
Miter Lock
Knob
Base Extension
Clamping lever
22.
Basic Saw Operations
Sliding Fence
Sliding Fence
Operating Sliding Fence
1. Turn the fence lever counter clockwise.
2. Slide the fence to the desired position.
3. Turn the fence lever clockwise
to tighten.
Removing the Sliding Fence
1. Lift up on the cover plate tab and
rotate clockwise.
2. Turn the fence lever counter clockwise.
3. Slide the fence as far as it will go to the left.
4. Lift up on the sliding fence to remove.
Adjusting the Sliding Fence
Lock - Make lock tighter
1. Remove the sliding fence.
2. Push down on the locking block to expose the
screw head.
3. Turn the screw counter clockwise to move it to
the next hex setting.
4. Replace the sliding fence
5. Check the clamping force in several positions.
Be sure the lever does not block the
clamp hole.
FRONT VIEW
Sliding Fence
Fence
Lever
REAR VIEW
Cover Plate Tab
Fence
Lever
Locking Block
Figure 25: Sliding Fence
Adjusting the Sliding Fence
Lock - Make lock looser
1. Remove the sliding fence.
2. Push down on the locking block to expose the
screw head.
3. Turn the screw clockwise to move it to the next
hex setting.
Replace the sliding fence
4.
5. Check the clamping force in several positions.
Be sure the lever does not block the clamp hole.
23.
Saw Operations
Chop Cut
During a chop cut, the slide rail lock knob is
•
tightened and the head assembly is lowered to
cut through the workpiece.
This type of cut is used mainly for narr
•
Follow these instructions for making your chop cut:
1. Slide the head assembly to the rear as far as it
will go (Figure 26).
2. Tighten the slide rail lock knob (Figure 26).
3. Properly position workpiece. Make sure workpiece is clamped firmly against the table and the
fence.
ow pieces.
Wait until blade comes to a complete stop
5.
before returning head assembly to the raised
position and/or removing workpiece.
Slide Lock
Knob Tightened
!
WARNING
switching on, lower head assembly to make sure
clamp clears guard and head assembly.
4. Activate the switch. Lower the head assembly
and make your cut.
Use clamping position that does not
interfere with operation. Before
Slide Cut
During a slide cut, the slide rail lock knob is loose,
•
the head assembly is pulled towards the operator,
the head assembly is lowered to the workpiece
and then pushed to the rear of the saw to make
the cut.
This type of cut is used mainly for wide pieces.
•
A positive blade hook of 10 degrees or more is
•
recommended for best performance when making aggressive cuts or cutting thicker materials.
See page 36 for accessory blade listing.
!
WARNING
up on top of the workpiece and force itself toward you.
Follow these instructions for making your
slide cut:
operly position workpiece. Make sur
Pr
1.
piece is clamped firmly against the table and
the fence.
!
WARNING
switching on, lower head assembly to make sure clamp
clears guar
NEVER pull the saw toward you during
a cut. The blade can suddenly climb
Use clamping position that does not
interfere with operation. Before
d and head assembly
.
e work-
Slide Completely
Against Rest
Figure 26. Chop Cut
4. Activate the switch. Lower the assembly all the
way down and cut through the edge of the workpiece.
5. Push (but do not force) the head assembly
towards the fence to the full rear position to
complete the cut.
6. Wait until blade comes to a complete stop before
returning head assembly to the raised position
and/or removing workpiece.
First:
Pull
Forward
Slide Rail
Lock Knob
Second:
Turn Saw
On, Lower
Head
Assembly
d:
Thir
Push
Blade Into
Workpiece
2. Loosen the slide rail lock knob (figure 27).
3. Grasp the switch handle and pull the head
assembly away fr
clears the workpiece or to its maximum extension if blade cannot clear the workpiece
(Figure 27).
om the fence, until the blade
24.
e 27. Slide Cut
Figur
Saw Operations
Miter Cut
• A miter cut is made at 0° bevel and any miter
angle in the range from 50° left to 60° right.
• The miter scale is cast-in on the table for easy
reading.
• Positive detents have been provided for fast and
accurate mitering at 0°, 15°, 22.5°, and 45° left
and right and 60° right.
• There are crown molding detents (left and right)
at 31.6° (see Cutting Crown Molding for more
information page 28).
• For off detent settings, use the detent override to
lock out the detent.
• A miter cut can be made as either a chop cut or
a slide cut depending on the width of the workpiece.
Follow these instructions for making your
miter cut:
1. Loosen miter lock knob. Lift miter detent trigger
and move the saw to the desired angle, using
either the detents or the miter scale. Tighten
miter lock knob (Figure 28).
!
WARNING
switching on, lower head assembly to make sur
clamp clears guard and head assembly.
3. Follow procedures for either chop cut or slide
cut (see page 24).
4. Wait until blade comes to a complete stop before
returning head assembly to the raised position
and/or removing workpiece.
Workpiece
Clamp
Use clamping position that does
not interfere with operation. Before
e
Workpiece
2. Properly position workpiece. Make sure work
piece is clamped firmly against the table and the
fence.
Bevel Cut
• A bevel cut is made at 0° miter and any bevel
angle in the range of 0° to 45°.
• There are factory set bevel stops at 0° and 45°. (See
ed.)
equir
Adjustment section if adjustments ar
• The bevel scale faces the operator for easy r
e r
eading.
Miter ScaleDetents
Figure 28. Miter Cut
• Ther
• A bevel cut can be made as either a chop cut or
• Use sliding fence and work supports as appropri-
e is a positive crown molding bevel stop at
33.9°. Disengage this stop unless using. (See
Cutting Crown Molding for details.)
a slide cut depending on the width of the workpiece.
ate. (See Sliding Base/Fence Extension page 23.)
Miter Lock
Knob
25.
Saw Operations
Bevel Cut (Continued from page 25)
Follow these instructions for making your
bevel cut:
1. To loosen, lift the bevel lock lever. Tilt the head
assembly to desired bevel angle. Tighten the
bevel lock lever (Figure 29).
2. Properly position workpiece. Make sure workpiece
is clamped firmly against the table and the fence.
!
WARNING
switching on, lower the head assembly to make sure
the clamp clears the guard and head assembly.
3. Follow the procedures for either a chop cut or
slide cut (see page 24).
Wait until blade comes to a complete stop before
4.
eturning head assembly to the raised position
r
and/or removing workpiece.
Use clamping positions that do not
interfere with operation. Before
Compound Cuts
• A compound cut is a cut requiring both a miter
setting and a bevel setting.
• A compound cut can be made as either a chop
cut or a slide cut depending on the width of the
workpiece.
Bevel
Angle
0º Miter
Bevel Lock Lever
Figure 29. Bevel Cut
3. Follow the procedures for either chop cut or slide
cut (see page 24).
4. Wait until blade comes to a complete stop before
returning head assembly to the raised position
and/or removing workpiece.
Workpiece
Clamp
orkpiece
W
• Because it may take several tries to obtain the
ed compound angle, perform test cuts on
desir
scrap material before making your cut.
Follow these instructions for making your
compound cut:
1. Extend the sliding fence and work supports when
making compound cuts that ar
left (see Sliding Base/Fence Extension on pages
22-23). Select the desir
(Figure 30). (See Miter Cut and Bevel Cut on page
25.)
operly position the workpiece. Make sur
Pr
2.
workpiece is clamped firmly against the table and
the fence.
!
WARNING
switching on, lower head assembly to make sur
clamp clears guard and head assembly.
Use clamping positions that do not
interfere with operation. Before
ed miter and bevel angles
e mitered to the
e the
e
26.
e 30. Compound Cut
Figur
orkpiece
W
Bevel
Angle
Workpiece
Clamp
Saw Operations
Cutting Grooves
(Dado Cut)
The depth stop adjustment is a featur
•
when cutting grooves (dados) in the workpiece.
The depth adjustment is used to limit blade
•
depth to cut grooves.
A groove can be cut as a slide cut.
•
1. Set the depth of cut by loosening the jam nuts on
the depth adjustment bolt (Figure 31). Do not
change the position of the two (2) jam nuts on the
end of the bolt.
2. Turn the depth stop bolt to the correct setting.
e used
Knurled Grip
Depth Stop Bolt
Jam Nuts
Depth Stop Base
Jam Nuts
Depth Stop
3. Tighten the jam nuts against the depth stop tab.
4. Cut the two outside grooves.
5. Use a wood chisel or make multiple passes by
sliding the wood over to one side to r
material between the outside grooves (Figure 32).
Grooves
Chisel Cut
Workpiece
Figure 32. Rough Cut Groove
emove the
e 31. Cutting Gr
Figur
ooves
Note: Auxillary fence is needed to get a con-
stant depth. The thickness of the fence
depends on the depth of the dado.
Depth Stop Tab
27.
Saw Operations
Cutting Base Molding
• 3 1/2” or smaller base molding can be cut vertical
against fence. All base molding can be cut flat on
the table, up to a maximum width of 12”.
• Follow the table for helpful hints on cutting
base molding.
• Cutting base molding can be done either as a
chop cut or a slide cut depending on the width of
the workpiece.
BASE MOLDING CUTTING INSTRUCTIONS
SETTINGS Vertical Position Horizontal Position
/ Back of molding is Back of molding is flat
INSTRUCTIONS against the fence on the table
Bevel Angle 0° 45°
Molding position Left Side
Inside Miter Angle Left at 45° Right at 45° 0° 0°
corner of wall
Molding Bottom Bottom Top against Bottom
position against table against table fence against fence
Right
Left
Outside Miter Angle Right at 45° Left at 45° 0° 0°
corner of wall
Finished Keep left Keep right Keep left Keep left
side side of cut side of cut side of cut side of cut
Right Side Left Side Right Side
Molding Bottom Bottom Bottom against Top against
position against table against table fence fence
Left
Right
Finished Keep left Keep right Keep right Keep right
side side of cut side of cut side of cut side of cut
Cutting Crown Molding
• Crown molding mustbe cut exactly to fit properly.
• There are two ways to cut crown molding:
flat on table or angled to table and fence.
our miter saw has special miter detents of
• Y
31.6° left and right and a bevel detent of 33.9°
for cutting cr
• These special detents angles have been
designed into your compound miter saw for the
standard cr
States with the following angles:
own molding flat on the table.
own molding used in the United
52° between the back of the molding and the
top flat surface that fits against the wall.
38° between the back of the molding and the
bottom flat surface that fits against the wall.
crown
NOTE:
molding.
• Even though these angles are standards, most
• Cutting cr
These detents cannot be used with 45
rooms do not have angles of exactly 90°, therefore, you will need to fine tune your settings
using the detent override.
own molding flat on the table can be
done either as a chop cut or a slide cut depending on the width of the workpiece.
°
28.
Saw Operations
Crown Molding Laying Flat on Table
Follow these instructions for cutting crown
molding:
1. Set the bevel and miter angles using Chart 1
below. Tighten the miter lock knob and the
bevel lock handle (Figur
e 33).
2. Position molding on saw table. Use the chart
below for correct position. Clamp workpiece in
place using the quick clamp.
NOTE: ALWAYS TAKE A TEST CUT USING
SCRAP TO CONFIRM CORRECT ANGLES.
!
WARNING
switching on, lower head assembly to make sure
clamp clears guard and head assembly.
3. Follow procedures for either chop cut or slide cut
(see page 24).
4. Wait until blade comes to a complete stop
before returning head assembly to the raised
position and/or removing workpiece.
Use clamping position that does not
interfere with operation. Before
Figure 33. Crown Molding Laying Flat
CROWN MOLDING CUTS - CUTTING METHOD #1 - FLAT ON TABLE
MAX. SIZE: 10-1/4"
F
E
N
C
E
ABLE
T
38º
W
A
L
L
52º CEILING
ANGLES OF U.S.
STANDARD MOLDING
INSIDE
CORNER
A
Workpiece
Clamp
33.9º
Bevel
31.6º Miter
C
B
OUTSIDE
CORNER
Crown
Molding
D
TYPE
OF (TABLE) (TILT) OF (TABLE) (TILT)
CUT
MITER
SETTNING
INSIDE CORNER
RIGHT
LEFT SIDE 31.6º 33.9º LEFT SIDE 31.6º 33.9º
PLACE TOP EDGE OF PLACE BOTTOM EDGE OF
MOLDING AGAINST FENCE - SA
VE LEFT END OF CUT
LEFT LEFT
RIGHT SIDE 31.6º 33.9º RIGHT SIDE 31.6º 33.9º
PLACE BOTTOM EDGE OF
MOLDING AGAINST FENCE - SAVE LEFT END OF CUT MOLDING AGAINST FENCE - SAVE RIGHT END OF CUT
BEVEL TYPE MITER BEVEL
SETTING
CUT
SETTNING
SETTING
OUTSIDE CORNER
RIGHT
CA
MOLDING AGAINST FENCE - SA
DB
PLACE TOP EDGE OF
VE RIGHT END OF CUT
29.
Saw Operations
Crown Molding Angled to
Table and Fence
• The advantage to cutting in this position is that
no bevel setting is required. Cutting is done with
45° miter angle.
• The maximum crown molding width that can be
cut and angled to table and fence is 4-1/4". The
preferred method for cutting crown molding with
this saw is with the molding laying flat on the
table at a maximum width of 10”. Crown stops
can be purchased as an accessory.
Follow these instructions for cutting crown
molding angled to table and fence.
1. Position the molding so the bottom (part which
is installed against the wall) is against the fence.
2. Set the miter angle using Chart 2. Tighten the
miter lock knob (Figure 34).
3. Support crown molding against the fence (see
“Body and Hand Position” on page 19.)
4. Follow the procedures for chop or slide cut (see
page 24).
5. Wait until blade comes to a complete stop
NOTE: ALWAYS TAKE A TEST CUT USING
SCRAP TO CONFIRM CORRECT ANGLES.
Figure 34. Crown Molding Angled to
Table and Fence
before returning head assembly to the raised
position and/or removing workpiece.
CROWN MOLDING CUTS - CUTTING METHOD #2 - ANGLED TO TABLE AND FENCE
MAX. SIZE: 4-
F
E
N
C
E
1
/4"
BOTTOM EDGE
52º
ABLE
T
38º
W
A
L
L
52º CEILING
ANGLES OF U.S.
ANDARD MOLDING
ST
A
INSIDE
CORNER
B
C
D
OUTSIDE
CORNER
TYPE MITER BEVEL TYPE MITER BEVEL
OF (TABLE) (TILT) OF (TABLE) (TILT)
CUT SETTNING SETTING CUT SETTNING SETTING
INSIDE CORNER
RIGHT
LEFT SIDE 45º 0º LEFT SIDE 45º 0º
SAVE RIGHT END OF CUT SAVE RIGHT END OF CUT
LEFT
RIGHT SIDE 45º 0º RIGHT SIDE 45º 0º
SAVE LEFT END OF CUT
OUTSIDE CORNER
CA
DB
VE LEFT END OF CUT
SA
RIGHT
LEFT
30.
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