Bosch 4410L User Manual

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Operating/Safety Instructions Instrucciones de funcionamiento y seguridad Consignes de fonctionnement/sécurité

4410L

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Safety

WARNING

“READ ALL INSTRUCTIONS” — Failure to follow the SAFETY RULES identified by BULLET (●) symbol listed BELOW and other safety precautions, may result in serious personal injur

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 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.

. If the plug does not fit fully in

● Do not expose power tools to rain or wet

conditions.

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.

Water entering a power tool will

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

Loose clothes, jewelry or long hair can be

parts.

caught in moving parts. Roll long sleeves above elbows. Rubber gloves and non-skid footwear are recommended when working outdoors.

● Avoid accidental starting. Be sure switch is

“OFF” before plugging in. Carrying tools with your finger on the switch or plugging in tools that have the switch “ON” invites accidents.

● Remove adjusting keys or wrenches before

turning the tool “ON”. A wrench or a key that is left attached to a rotating part of the tool will be thrown.

● Do not overreach, keep proper footing and

balance at all times. Proper footing and balance enables better control of the tool in unexpected situations.

● Do not stand on tool or its stand. Serious

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

“SAVE THESE INSTRUCTIONS”

Safety

WARNING

● 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 glasses.

“READ ALL INSTRUCTIONS” — Failure to follow the SAFETY RULES identified by BULLET (●) symbol listed BELOW and other safety precautions, may result in serious personal injur

safety

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.

of unauthorized parts or failure to follow Maintenance Instructions may create a hazard.

Use

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 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.

causes excessive sparking and will damage the lower guard and will overload the motor. (NOTE: Bosch Tool Corporation does not offer 10” metal cutting blades.)

Cutting ferrous materals

, leading to

“SAVE THESE INSTRUCTIONS”

Safety

WARNING

● Inspect your workpiece before cutting. If

“READ ALL INSTRUCTIONS” — Failure to follow the SAFETY RULES identified by BULLET (●) symbol listed BELOW and other safety precautions, may result in serious personal injur

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 20).

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

● Braking action of the saw causes the saw

head to jerk downward. Be ready for this reaction when making an incomplete cut or

when releasing the switch before the head is completely in the down position.

● After finishing the cut, release the switch,

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

REACHING WITH YOUR HAND UNDER A COASTING BLADE IS DANGEROUS!

● There are additional safety instructions

for particular operations of the saw in the operating section. Read the rest of the manual for safe operation.

● For 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 interfere with the guard and head assembly. Second, turn saw “ON” and lower the saw to the table. Then PUSH saw through the workpiece. Release the switch and wait for the blade to completely stop before raising the head assembly and removing the workpiece.

Never “pullcut” since blade may climb the workpiece causing KICKBACK.

● For chop action cutting, slide the head

assembly to the rear as far as it will go and tighten slide lock knob. Then 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.

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”

Safety

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

WARNING

● Do not allow familiarity gained from frequent

use of your miter saw to become commonplace.

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.

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 (●) symbol listed BELOW and other safety precautions, may result in serious personal injury.

Always remember that a careless frac-

THE WARNINGS SHOWN BELOW CAN BE FOUND ON

WARNING

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.

Some dust created by power sanding, sawing, grinding,

“SAVE THESE INSTRUCTIONS”

Safety

WARNING

“READ ALL INSTRUCTIONS” — Failure to follow the SAFETY RULES identified by BULLET (●) symbol listed BELOW and other safety precautions, may result in serious personal injur

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 requires

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

“SAVE THESE INSTRUCTIONS”

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.

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

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 pected 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 have it serviced immediately.

WARNING

Remember to let the saw blade come to a complete stop before raising the blade from the workpiece. 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

, but unex-

use saw and

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

Table of Contents

Safety...................................................................2-6

General Safety Rules for Bench

Safety Rules for Miter Saws..............................3-6

Electrical Requirements........................................

Table of Contents ..................................................7

Getting To Know Your Miter Saw......................8-9

Assembly.........................................................10-12

Unpacking & Checking Contents .......................10

Tools for Assembly & Alignment .........................10

Installation & Removal of the Blade ..............11-12

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........................16

Kerf Insert...........................................................17

Depth Adjustment...............................................17

Slide Action Adjustment......................................18

Transporting, Placement & Mounting...........19-20

Mounting Applications ........................................19

Mounting the saw ...............................................20

Adjusting the Four Position Switch Handle ........20

Basic Saw Operations....................................21-24

Body and Hand Position.....................................21

Workpiece Support........................................22-23

Top Tools ..........2

Switch Activation ................................................23

Detent Override

Microfine Miter Adjustment.................................24

Sliding Fences and Base Extensions

Saw Operations ..............................................26-34

Chop Cut ............................................................26

Slide Cut.............................................................26

Miter Cut.............................................................27

Bevel Cut.......................................................28-29

Compound Cuts .................................................29

Cutting Grooves ................................................30

Length Stop ........................................................30

Cutting Base Molding .........................................31

Cutting Crown Molding..................................31-33

Special Cuts .......................................................34

Maintenance & Lubrication ...........................35-36

Carbon Brushes .................................................35

Belt Replacement ...............................................35

Cleaning .............................................................35

Care of Blades....................................................36

Tool Lubrication ..................................................36

Bearing ...............................................................36

Troubleshooting .............................................36-37

Electrical Troubleshooting ..................................36

General Troubleshooting ....................................37

Accessories..........................................................38

Warranty..............................................................116

..................................................24

.................25

Getting To Know Your Miter Saw

WARNING

outlet before making any adjustments.

1. Switch Lock-Off Release Button – One of these

two buttons must be pressed before the power switch can be pressed.

2. Power Switch – The power switch used with the

“Lock-OFF” button energizes the unit.

3. Main Handle – This handle contains the power

switch. Pulling this handle down lowers the blade into the workpiece.

4. Brush Caps – These caps keep the motor brush-

es in position and provide easy access for inspecting and replacing brushes.

5. Lower Blade Guard/Lower Guard Lip – The

lower blade guard helps protect your hands from the spinning blade. It retracts as the blade is lowered. Lip can be used to raise the lower guard when guard becomes jammed on a workpiece.

6. Blade – Use only 10" blades with 5/8" 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 Inserts – Kerf inserts can be adjusted to dif-

ferent blade widths to minimize workpiece tear-out.

9. Miter Detent Override – Allows detent action to

be locked out allowing for micro adjustments to any miter angle.

10. Miter Scale/Miter Angle Indicator – This scale is

cast in on the base of the saw. Indicator is fastened to the table.

11. Miter Detents – There are ten (10) miter detent

slots for fast and accurate miter cuts of common miter angles.

12. Miter Detent Lever – The lever releases the

table from the detent.

13. Miter Lock Knob – The miter lock knob locks the

miter saw table at any desired miter angle.

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 – The four corners of the

saw provide areas to clamp, bolt or nail the saw to a flat work surface.

17. Sliding Base Extensions – These extensions

provide extra workpiece support and are espe cially useful when cutting long workpieces.

18. Base Extension Clamping Levers – Locks the

base extensions at desired positions.

19. Length Stop – For repetitive cuts of the same

length. Can be moved to left side, if desired.

20. Dust Port – The dust port can accommodate the

dust chute and dust bag or optional VAC004 Vacuum Hose Adapter, which accepts Bosch 35mm hoses.

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

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

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

23. Microfine Miter Adjustment System – Allows for fine adjustment (up to 2 degrees to the left or right) of the detent angles.

24. Slide Rail Lock Knob – Locks the slide rails when not making slide cuts or when transporting the saw.

25. Slide Rails – Guide the head assembly when making slide cuts.

26. Quick-Action Clamp Position Holes – There are two (2) holes (not shown) behind the fence for placing the quick action clamp.

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

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

29. Cord Wrap – Allows you to easily wrap up the cord so it’s out of the way when transporting or storing.

30. Power Cord – Supplies power to motor.

31. Rear Cover Tool Storage – Storage for

10mm/17mm Combination Open End Wrench and 1.5mm & 3mm Hex “L” Wrenches.

32. 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.

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

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

35. Quick Release Depth Stop Button – Allows you to quickly release the depth stop.

36. Depth Stop Fine Adjustment Knob–Allows you to adjust the depth of the blade for cutting grooves in the workpiece.

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

Rear Carrying Handle –

38.

tool.

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

40. Arbor Lock—Keeps the blade from rotating while

tightening or loosening arbor screw during blade

replacement or removal.

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

42. Dust Bag and Dust Elbow – Used to collect saw

dust.

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

Arbor Laser / 3x Battery

44.

° to 45° left, 0° to 45° right,

Used for lifting of the

Unpacking & Checking Contents

WARNING

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 damage. 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 4410 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.

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

Tools for Assembly & Alignment

Check List of Loose Parts:

■■

Quick- Action Clamp (Item #25 on page 8)

■■

Dust Elbow/Dust Bag (Item #42 on page 9)

Multi Purpose Tool (See below)

■■

Miter Lock Knob (Item #13 on page 8)

■■

1.5mm Hex “L” Wrench (See below)

3mm Hex “L” Wrench (See below)

■■

10mm/17mm Combination Open-End Wrench

(See below)

■■

Arbor Laser / 3x Battery / Arbor Laser Manual

WARNING

until the missing parts are obtained and are installed correctly.

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

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

(supplied, stored on the right rear base)

Combination Square (not included)

Combination Square Must be True

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

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

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

10mm/17mm Combination Open End Wrench

(supplied, see figure below)

1.5mm & 3mm Hex “L” Wrench

(supplied, see figure below)

Rear Cover Tool Storage

The Open End Wrench and Hex Wrenches are stored on the inside rear cover of the saw. To remove the cover, unscrew the two top and center thumb screws.

Thumb

Screws

10.

Assembly

Installation And Removal Of The Blade

WARNING

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 #40 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. Install 10" blade onto the arbor shaft (Figure 3). NOTE: Make sure the rotation arrow on the blade

matches the clockwise rotation arrow on the lower guard.

WARNING

and 5/8" arbor. Smaller blades will not cut workpiece all the way through and larger blades will cut into table and/or blade guards.

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

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

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

WARNING

guard will not function properly.

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

turns freely

WARNING

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 autho rized service.

Disconnect plug from power source before performing any assembly

To avoid injury, do not use a blade larger or smaller than 10" diameter

Never use saw without cover plate securely in place. Lower

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

Blade Bolt

Figure 1. Blade Removal

Outer Washer

Blade Bolt

(Left Hand Thread)

Figure 2. Blade Hardware

Lower Guard

Cover Plate

Outer

Washer

Front & Rear

Cover Plate Screws

Sawblade

Arbor

Shaft

Inner

Washer

Inner

Washer

11.

Upper Guard

Figure 3. Blade Installation

Arbor

Shaft

Assembly (continued)

Attaching Miter Lock Knob

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

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. Make sure dust bag does not interfere with the slide rails during slide cutting.

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.

NOTE: The dust port accepts the Bosch VAC004 Vacuum Hose Adapter, which allows connection to a Bosch 35mm vacuum hose.

WARNING

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. W sheeting and persons not protected should be kept out until work area is thoroughly cleaned.

When sawing chemically pressure treated lumber

ork area should be sealed by plastic

, paint that may be

Miter Gauge

Lock Knob

Figure: Miter Lock Knob

Dust Bag

Figure: Dust Elbow and Dust Bag

Shaft

Dust Elbow

Dust

Port

12.

Adjustments

WARNING

adjustment or repair to avoid possible injury.

NOTE: Your miter saw was completely adjusted at the factory alignment may have occurred. Check the following settings and adjust if necessary prior to using this miter saw.

Disconnect plug from power source before performing any assembly,

. However, during shipment, slight mis-

Checking 0° Bevel

Adjustment

1. Lower head assembly and engage head assembly

lock pin.

2. Slide head assembly completely to the back and

tighten the rail lock knob.

3. Rotate table to 0° miter position

4. Pull up bevel lock lever to unlock bevel.

5. Check position of bevel range selector knob, it

should be at the 0°-45° position.

6. 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.

Remove rear cover to expose bolts.

2. Lift bevel lock lever to release bevel lock.

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

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

Figure 2. Calibrating Blade at 0 degrees

(90° to the table)

Table

Blade

Combination

Square

Figure 1. Blade Square to Table

Bevel Lock

Lever

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

6. While rotating bolt head “C”, watch the saw blade tilt until it is aligned with the combination square.

Tighten setscrew “D”.

8. Tighten 10mm bolt heads “A” & “B”

9. Check and adjust bevel pointers 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.

13.

Adjustments (continued)

WARNING

adjustment or repair to avoid possible injury.

Disconnect plug from power source before performing any assembly,

Checking Right 45°

Bevel Stop

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

2. Slide head assembly completely to the back and tighten the rail lock knob.

3. Rotate table to the 0° miter position.

4. Pull up bevel lock lever to unlock bevel.

5. Move bevel range selector knob to “0°-45° Right” position. (See page 28)

6. 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.

7. 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.

Calibrating Right 45°

Bevel Stop

1. Lift bevel lock lever to release bevel lock.

2. Tilt saw to 45° right bevel position.

Position combination square with 45° surface

3. against blade. (Figure 1)

Insert 3 mm “L” wrench into hole in vertical support

4. 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.

Combination

Square

Figure 1. Right 45° Bevel Stop

3mm

“L”

Wrench

Adjusting

Access Hole

Bevel

Pointer

14.

Figure 2. Right 45° Bevel Adjustment

Checking Left 45°

Bevel Stop

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

Slide head assembly completely to the back and

2. tighten the rail lock knob.

3. Rotate table to the 0° miter position.

4. Pull up bevel lock lever to unlock bevel.

5. Move bevel range selector knob to 45°-0° position. (See page 28)

6. 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.

7. 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.

Combination Square

Figure 1. Left 45° Bevel Stop

Table

Blade

Bevel Lock

Lever

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.

Figure 2. Left 45° Bevel Adjustment

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

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

If necessary

, repeat steps 1–5 to adjust the tension.

15.

Adjustments (continued)

22.5

31.6

WARNING

adjustment or repair to avoid possible injury

Disconnect plug from power source before performing any assembly,

Blade Square to Fence

1. Slide saw forward so blade is near the center of the table and tighten slide rail lock knob.

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

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

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

5. Loosen rail lock knob and slide head assembly back to check squareness of complete slide cut against the square’s ruler.

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

Knob

Combination Square

Figure 1. Blade Square to Fence

Hex

Bolts

Hex

Bolts

Figure 2. Fence Adjustment

Blade

Fence

Knob

Miter Scale

Indicator

Adjustment

Indicator Adjustment

miter position and tighten miter

Set table at the 0

1. lock knob.

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

Loosen the Phillips screw that holds the indicator

Screw

in place.

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

Mark

Miter Scale

Indicator

Figure: Miter Scale Adjustment

16.

Kerf Insert

22.5

31.6

Kerf Screws

The kerf insert should be adjusted close to the blade, but without touching the blade, in order to avoid tearout on the bottom of the workpiece.

1. Lower the head assembly and lock into position.

2. Loosen the six (6) kerf screws using the multi pur-

Kerf

Inserts

pose tool.

3. Adjust the kerf inserts as close to the blade (teeth)

as possible without touching the blade.

4. Tighten the kerf screws.

NOTE: At extreme bevel angles the saw blade may slightly cut into kerf insert.

Figure: Kerf Insert

Depth Adjustment

• When the diameter of the blade has been reduced

due to sharpening, it may be necessary to adjust the depth stop. When a new blade is installed, it is necessary to check the clearance of the blade to the turn table structure.

Setting Blade Depth for

Normal Full Cuts

• The depth stop adjustment is a feature used when

cutting grooves in the workpiece. (See page 28 for cutting grooves.)

1. Loosen and turn both of the lower Jam Nuts to just

above the threaded end of the Depth Stop Bolt.

2. Press Depth Stop Release Button and pull up

Depth Stop Bolt until nuts hit the bottom of its support frame.

3. Set the table to the 0° miter position. Push down

and slide back saw head to the full back position.

While looking at both the blade and the corner

where the fence meets the table, turn the Depth

CAUTION

the blade and the turn table structure. The blade

could be ruined if it cuts into the table structure. Stop Bolt to set the blade depth to about 1/4 inch below the table’

s surface.

5. Release the saw head to the up position.

Turn both lower Jam Nuts to be tight against the

6. ighten nuts against

bottom of the support frame. each other

7. Practice slide cutting (with tool unplugged) to veri-

The depth stop can be easily adjusted to limit the cutting depth, such as when creating a rough slot.

fy that the blade does not touch table. If it clears the table, make a practice cut (with tool plugged) on scrap wood to verify that the cut goes completely through the lower front edge of the workpiece

Figure: Depth Adjustment

Do not start the miter saw without checking for interference between

Setting Blade Depth for

Cutting Grooves

(See page 30 for instructions)

Depth Stop Bolt

Upper Jam Nuts

Depth Stop

Release Button

Lower Jam Nuts

17.

Adjustments (continued)

WARNING

adjustment or repair to avoid possible injury.

Disconnect plug from power source before performing any assembly,

Slide Action Adjustment

1. Locate the 4 Set Screws (A, B, C, & D) on the Rail

Guide Housing. (Figure 1)

2. Loosen the Nut on Set Screw (A) with an

adjustable wrench.

3. Tighten or loosen Set Screw (A) with the 4mm end

of the bit on the multi-purpose tool until you achieve minimal slide play while maintaining the desired sliding force.

4. After adjusting Set Screw (A), hold Set Screw (A)

with a 4mm allen key and tighten the nut with an adjustable wrench without moving the Set Screw. (Figure 2)

5. Complete steps 2-4 with the remaining set screws

in order as shown in figure 1.

Figure 1. Set Screws

18.

Figure 2. Adjust and Tighten Set Screw

Transporting, Placement & Mounting

WARNING

• Unplug electric cord. Before transporting the saw,

rotate head and lock assembly to 60° right miter, lock into detent, slide head assembly to the middle

s rail, tighten the slide rail lock knob and lock

of it’ the head assembly in the lowered position.

To avoid injury always observe the following:

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 carry the tool by the slide rails, this may cause blade damage.

• 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.

CAUTION

crack foot or damage base.

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

Mounting Applications

Mounting to Workbench

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

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

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

Drill four (4) 5/16" diameter holes through work-

3. bench.

Place the miter saw on the workbench aligning

4. 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 slide com pound miter saw

Front Carrying

Rear Carrying

Handle

Figure: Workbench Mounting

Handle

Bolt Hole

Nail Hole

19.

Transporting, Placement & Mounting

Mounting Applications

Portable Mounting Using Clamps

If necessary 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.

, clamp the miter saw to a workbench or

Adjusting the Four Position Switch Handle

Handle

Lock

Clamp

Clamping

Areas

Clamping Areas

Figure: Portable Mounting Using Clamps

Handle

Rotation

Release

Lever

Figure: Setting Main Handle Position

Setting Main Handle in

Desired Position

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

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

To reposition the main handle:

1. Release handle lock clamp.

2. Pull and hold handle rotation release lever

3. Rotate handle to desired location.

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

Note: Power switch can not be actuated unless

release lever is retracted down. Do not attempt to switch tool on between handle position, damage may

occur

5. Lock the handle clamp.

Adjusting the Four-Position Handle

Lock Clamp Tension

1. Open handle lock clamp.

2. Using 1.5 mm Allen wrench, increase tension by turning both setscrews 1/4 turn to the left, tighten by turning to the right. setscrews by the same amount.

3. Close handle lock clamp.

4. Check the tension.

Always adjust both

20.

Basic Saw Operations

Body and Hand Position

WARNING

safer. Observe the following instructions (Figure 1).

Position your body and hands properly to make cutting easier and

Correct Incorrect Use

= Projected Line Of Cut

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.

Y RUN—

will intersect with the workpiece during cutting operations. Always perform the simulated cutting sequence 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.

It is important to know where the blade

with the power tool switched OFF to gain

• Hold workpiece firmly against table and fence to

prevent movement.

• Keep hands in position until trigger has been

released and blade has stopped completely.

• Never place hands on slide rails.

• 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.

WARNING

For example, when trying to cut work-pieces that are near the maximum cutting height capacity. Under these conditions or during the sliding motion of cut, the workpiece can stop the lower guard movement before the downward motion of the arm could preopen 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.

The lower guard may not automatically open under certain cutting conditions.

Lip

Lower Guard

Workpiece

21.

Figure 2. Raising Lower Guard

Basic Saw Operations (continued)

Workpiece Support

WARNING

fully supported along their entire length.

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

Clamps

Quick-Action Clamp - This clamp easily secures a

workpiece in either of two (2) clamp holes behind the fence (Figure 1).

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

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

• With clamp in open (lever raised) position, insert clamp into clamp post until rubber foot comes into contact with material.

• Press down on lever to tighten clamp.

• Move the head assembly to check clearance with

clamp.

• Pull up on lever to release clamp.

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.

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

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). (See also Length Stop on page 30.)

Extra-Long Base Extension Rods – The optional MS1229 Base Extension Kit allow the base extensions to extend out to 50-1/2”. Even after these longer rods are installed, the base extensions can be fully retracted for transportation and storage.

Sliding

Base

Extensions

Quick-Action

Clamp

Post

Clamp

Hole

Screw Rod

Figure 1. Quick-Action 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.

Hole

Clamp Levers

Figure 2. Sliding Base Extensions

Blocks - The base height (3-3/4") is designed to

match the standard lumber of two 2x’ Boards of these thicknesses can be used to create auxiliary support extensions for long workpieces (Figure 3).

Two 2x’s

and One 1x’s

Figure 3. Block Support

s and one 1x.

22.

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.

Place a piece of wood against the miter saw fence.

(Wood can have a maximum height of 4-1/2". Check that auxiliary fence assembly does not interfere with head assembly.)

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

2. Mark the locations of the support holes on the

wood from the back side of the fence.

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

support board.

4. Attach (each) auxiliary fence using two (2)

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

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

5. Make a full depth cut to create the blade slot.

Check for interference between the auxiliary fence and the lower blade guard. Make adjustments as necessary.

WARNING

Blade Slot

Auxiliary

Fence

Check for interference from any components.

Flat Head

Machine Screws

Figure: 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 “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.

Switch “Lock-Off”

Release Button

Power

Switch Lever

Figure: Switch Activation

23.

OFF ENGAGED

Basic Saw Operations (continued)

22.5

31.6

Bevel Lock

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.

o 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

Lock Knob

Miter

Detent Lever

Figure: Detent Override

Microfine Miter Adjustment

System

This feature allows you to move the turntable by very small increments up to 2 degrees to the left or right of the detent angles (except 60° detent) to reach to the desired miter angle.

1. Move the table to the detented angle that is to be

adjusted (Figure 1).

2. The miter detent lever's red override feature

Angle Detents

MUST be engaged, as described above.

Push the Microfine

'ENGAGED' position. This engages the system

Adjustment knob forward to

Figure 1. Miter Scale Indicator

into the detent slot (Figure 2).

Note: You may have to rotate the table slightly to engage the system.

urn knob until pointer comes to desired angle.

Rotating the knob forward causes the table to

• rotate to the left.

• Rotating the knob backward causes the table to

Miter

Lock Knob

rotate to the right.

Use miter lock knob to lock table in place before

5. cutting.

6. To release table from Microfine Adjustment System, simply pull knob away from table until in snaps into 'OFF' position.

NOTE: Microfine must be returned to the ‘OFF’

Figure 2. Microfine Adjustment System

position in order to use the standard detent system.

Miter Scale

Indicator

Microfine

Adjustment

knob

24.

Sliding Fences and Base Extensions

WARNING

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.

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 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.

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.

ighten knob

After the cut is complete, reinstall the sliding fence.

o reinstall the sliding fence, reverse this procedure.

CAUTION

always be secured in the fully closed position.

See page 22 for information about other types of workpiece support.

So as to provide sufficient (minimum 6”) spacing from hand to saw

Sliding Base:

Base Extensions:

Sliding Fence:

During transportation, sliding base extensions and fences should

Sliding

Fence

Base

Extension

Base Extension

Clamping lever

Figure: Sliding Fences and Base Extensions

25.

Saw Operations

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 narrow pieces. Follow these instructions for making

your chop cut:

1. Slide the head assembly to the rear as far as it will

go.

2. Tighten the slide rail lock knob.

3. Properly position workpiece. Make sure workpiece

is clamped firmly against the table and the fence.

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.

5. 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

Slide Rail

Lock Knob

Slide Completely

Against Rest

Figure: Chop Cut

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.

WARNING

climb up on top of the workpiece and force itself toward you.

1. Properly position workpiece. Make sure workpiece is

clamped firmly against the table and the fence.

WARNING

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

2. Loosen the slide rail lock knob.

Grasp the switch handle and pull the head assembly

away from the fence, until the blade clears the work piece or to its maximum extension if blade cannot clear the workpiece.

4. Activate the switch. Lower the assembly all the way

down and cut through the edge of the workpiece.

NEVER pull the saw toward you during a cut.

Follow these instructions for

making your slide cut:

Use clamping position that does not interfere with operation. Before

The blade can suddenly

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.

Figure: Slide Cut

26.

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 31).

For precision settings at angles next to the

•

detents, detent. This prevents the wedge on the detent lever from slipping back into the detent.

A miter cut can be made as either a chop cut or a

•

slide cut, depending on the width of the workpiece.

The kerf inserts should be as close to the blade as

•

possible without touching the blade (see Kerf Inserts for adjustment procedures).

use the detent override to lock out the

Quick Action Clamp

Workpiece

Miter

Scale

Figure: Miter Cut

Detents

Miter Lock

Knob

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 25).

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

WARNING

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

4. Follow procedures for either chop cut or slide cut (see page 26).

Wait until blade comes to a complete stop before

5. returning head assembly to the raised position and/or removing workpiece.

Use clamping position that does not interfere with operation. Before

27.

Saw Operations (continued)

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.)

• A bevel cut can be made as either a chop cut or a

slide cut depending on the width of the workpiece.

• The front-positioned bevel lock lever locks the

head assembly at the desired bevel angle.

Bevel

Lock

Level

Bevel Range

Selector Knob

Figure 1.

Front Carry

Handle

Bevel Range Selection

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

45°-0

Left

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

(This left bevel range is the default setting)

a. Extend left sliding fence to clear saw assembly and

re-lock (Figure 2).

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

c. Grasp the front carry handle with right hand and tilt

saw head to angle desired (Figure 2).

d.Push down bevel lock lever until you feel the lever

snap into the locked position.

0-45°

Right

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

Extend right sliding fence to clear saw assembly

and re-lock (Figure 2).

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

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.

Sliding

Fence

Figure 2.

e. Push down bevel lock lever until you feel the lever

snap into the locked position.

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

This is designed to regain the pre-set

Max

Range

o operate in Bevel Range 47

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

° Left to 46° Right:

28.

slightly to the left while rotating the bevel range selector knob with left hand to “Max Range” (Figure 2).

Tilted saw head to any angle from 47° left to 46°

right.

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 25).

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).

• A compound cut can be made as either a chop cut

or a slide cut depending on the width of the workpiece.

• 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 25.)

2. Properly position workpiece. Make sure workpiece

is clamped firmly against the table or the fence.

WARNING

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

Set miter and bevel angles according to the

instructions on page 28 for miter and bevel cuts.

4. Follow the procedures for either chop cut or slide

cut (see page 26).

5. 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

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.

Follow the procedures for either a chop cut or slide

4. cut (see page 26).

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

Quick-Action

Clamp

Workpiece

Sliding

Base

Bevel Angle

Scale

Figure: Compound Cut

Miter

Angle

29.

Saw Operations (continued)

Cutting Grooves

The depth stop adjustment is a feature used when

•

cutting grooves in the workpiece.

The depth adjustment is used to limit blade depth to

•

cut grooves.

A groove should be cut as a slide cut.

•

1. For major adjustments, press the depth stop release button and slide the depth stop bolt to the desired location (Figure 1).

2. For minor adjustments, simply rotate the depth stop bolt to the desired location.

3. The upper jam nuts can be used to set a commonly used groove depth. To adjust, loosen the upper jam nuts, move to desired location, and tighten against each other.

4. Cut the two outside grooves.

5. Use a wood chisel or make multiple passes by sliding the wood over to one side to remove the material between the outside grooves (Figure 2).

Depth Stop Bolt

Upper Jam Nuts

Depth Stop

Release Button

Lower Jam Nuts

Figure 1. Cutting Grooves

Outside Grooves

Workpiece

Chisel Cut

Length Stop

WARNING

could trap workpiece and could cause workpiece to be thrown.

The unit’ making repetitive cuts of the same length.

To set the stop, simply unscrew the knob, flip the stop into position and tighten the knob.

clamping lever length stop, and relock the levers.

The maximum length that can be cut using the

length stop is approximately 18’.

If desired, the length stop and knob can be moved to the left base extension. Stop Kit can also be installed on the left side to provide stops on either side of the saw

To increase the length that can be cut using the length stop, replace the tool’ with the optional MS1229 Extra-Long Base Rod Kit,

s flip up length stop can be used when

o set the cut length, unlock the base extension

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

, reposition the base extension and

The optional MS1230 Length

s base extension rods

Figure 2. Rough Cut Groove

Length

Stop

Figure: Length Stop

which increases the maximum length that can be cut using the length stop to approximately 25’ side of the blade.

Knob

on either

30.

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