Bosch 5412L User Manual
IMPORTANT: IMPORTANTE: IMPORTANT :
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Operating/Safety Instructions
Instrucciones de funcionamiento y seguridad
Consignes de fonctionnement/sécurité
5412L
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See page 2 Ver página 38 Voir page 74
!
WARNING
al injury.
Safety
READ ALL INSTRUCTIONS” — Failure to follow the SAFETY RULES identified by
“
BULLET (●) symbol listed BELOW and other safety precautions, may result in serious person-
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.
tools create sparks which may ignite the dust or
fumes.
● Keep bystanders, children and visitors away
while operating a power tool.
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.
shock if your body is grounded.
. If the plug does not fit fully in
There is an increased risk of electric
Power
Distractions
● Do not expose power tools to rain or wet
conditions. Water entering a power tool will
increase the risk of electric shock.
● Do not abuse the cord. Never use the cord
to carry the tools or pull the plug from an
outlet. Keep cord away from heat, oil, sharp
edges or moving parts. Replace damaged
cords immediately.
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.
Damaged cords increase
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”
2.
Safety
!
WARNING
al injury.
● Use safety equipment. Always wear safety
goggles.
hearing protection must be used for appropriate
conditions. Everyday eyeglasses only have
impact resistant lenses, they are NOT safety
glasses.
“READ ALL INSTRUCTIONS” — Failure to follow the SAFETY RULES identified by
BULLET (
Dust mask, safety shoes, hard hat or
●) symbol listed BELOW and other safety precautions, may result in serious person-
Tool Use and Care
● Use clamps or other practical way to secure
and support the workpiece to a stable platform.
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.
Holding the work by hand or against your
“SAVE THESE INSTRUCTIONS”
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.
ed” i.e. holding the left side of the workpiece
with your right hand is very dangerous.
● Always disconnect the power cord from the
power source before making any adjustments or attaching any accessories. You
may unintentionally start the saw, leading to
serious personal injury.
● Miter saws are intended to cut wood or
woodlike products, they cannot be used with
abrasive cutoff wheels for cutting ferrous
material such as bars, rods, studs, etc.
However, if cutting materials like aluminum
or other non-ferrous metals, use only saw
blades specifically recommended for nonferrous metal cutting. Cutting ferrous materi-
als causes excessive sparking and will damage
the lower guard and will overload the motor.
(NOTE: Robert Bosch
offer 12” metal cutting blades.)
Supporting the workpiece “cross hand-
ool Corporation doe not
T
3.
!
WARNING
l injury.
a
Safety
READ ALL INSTRUCTIONS” — Failure to follow the SAFETY RULES identified by
“
BULLET (
●) symbol listed BELOW and other safety precautions, may result in serious person-
● Inspect your workpiece before cutting. If
orkpiece is bowed or warped, clamp it with
w
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
inch the blade and be torn from your hand.
p
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
to free the jammed material.
, then work
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”
4.
Safety
DESIGNATED DANGER ZONE.
AVOID POSITIONING HANDS,
FINGERS OR ARMS IN THE
AREA DESIGNATED BY THIS
SYMBOL.
READ ALL INSTRUCTIONS” — Failure to follow the SAFETY RULES identified by
!
WARNING
injury.
● 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
SER
VE AS A REMINDER OF ALL SAFETY RULES
NEEDED FOR SAFE OPERATION OF THIS MITER
SAW.
“
BULLET (●) symbol listed BELOW and other safety precautions, may result in serious personal
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”
5.
!
WARNING
njury.
i
Safety
READ ALL INSTRUCTIONS” — Failure to follow the SAFETY RULES identified by
“
BULLET (
●) symbol listed BELOW and other safety precautions, may result in serious personal
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
amaged cords can shock, burn or electrocute.
d
● 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
Rating Cord Size in A.W.G.
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
Cord Length in Feet
25 50 100 150
“SAVE THESE INSTRUCTIONS”
Table of Contents
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
General Safety Rules For Bench Top Tools . . . . 2
Safety Rules For Miter Saws . . . . . . . . . . . . . 3-6
Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . 6
Electrical Requirements. . . . . . . . . . . . . . . . . . . .
Getting To Know Your Miter Saw. . . . . . . . . . . 8-9
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tools Needed for Assembly and Alignment . . . 10
Unpacking and Checking Contents . . . . . . . . . 10
Installation and Removal of the Blade. . . . . 11-12
Assembling Dust Elbow and Dust Bag
Adjustments. . . . . . . . . . . . . . . . . . . . . . . . . . 13-16
Checking 0° Bevel Adjustment . . . . . . . . . . . . . 13
ension. . . . . . . . .
Adjusting Bevel Lock Lever
Blade 45
Blade Square To Fence . . . . . . . . . . . . . . . . . . 15
Miter Scale Indicator Adjustment . . . . . . . . . . . 15
Kerf Insert . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Depth Adjustment . . . . . . . . . . . . . . . . . . . . . . . 16
Transporting, Placement and Mounting . . 17-18
Mounting Applications. . . . . . . . . . . . . . . . . . . . 17
Mounting the saw
° To The Table . . . . . . . . . . . . . . . . . . 14
. . . . . . . . . . . . . . . . . . . . . . . 18
T
10-12
. . . . . . .
12
13
NOTE: The smaller the gauge number, the heavier
the cord.
Adjusting the Four Position Switch Handle . . . 18
Basic Saw Operations . . . . . . . . . . . . . . . . .
Body and Hand Position. . . . . . . . . . . . . . . . . . 19
Workpiece Support . . . . . . . . . . . . . . . . . . . 20-21
7
Switch
Detent Override . . . . . . . . . . . . . . . . . . . . . . . . 22
Sliding Base/Fence Extension . . . . . . . . . . . . .
Saw Operations . . . . . . . . . . . . . . . . . . . . . . .
Chop Cut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Slide Cut
Miter Cut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Bevel Cut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Compound Cuts . . . . . . . . . . . . . . . . . . . . . . . . 26
Cutting Grooves . . . . . . . . . . . . . . . . . . . . . . .
Cutting Base Molding
Cutting Crown Molding . . . . . . . . . . . . . . . . 28-30
Special Cuts . . . . . . . . . . . . . . . . . . . . . . . . 31-33
Maintenance and Lubrication . . . . . . . . . . . 34-35
Belt Changes. . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . 35-36
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Activation. . . . . . . . . . . . . . . . . . . . . . . . 21
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . 28
19-22
22
23-30
23
27
6.
Electrical Requirements
1. Connect this saw to a 120V, 15-amp branch circuit 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.
!
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
28
25
20
26
2
4
1
3
1
5
41
7
8
9
18
17
!
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.
Power Switch–The power switch used with the
2.
“Lock-OFF” button energizes the unit.
Main Handle–This handle contains the power
3.
switch. Pulling this handle down lowers the blade
into the workpiece.
Brush Caps–These caps keep the motor brush
4.
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 12" blades with 1" arbor hole.
7. Sliding Fence – Supports the workpiece.
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 tearout.
18
16
15
14
To avoid injury from accidental starting, remove plug from power source
11
The
13
10
9. Miter Detent Override – Allows detent action to
10. Miter Scale/Miter Angle Indicator – This scale
11. Miter Detents – There are ten (10) miter detent
12. Miter Detent Lever –
-
13.
14. Table – Sits in base, provides workpiece support,
15.
16. Tool Mounting Pads – The four corners of the
17. Sliding Base Extensions – These extensions
-
21
11
be locked out allowing for micro adjustments to
any miter angle.
is cast in on the base of the saw. Indicator is fastened to the table.
slots for fast and accurate miter cuts of common
miter angles.
table from the detent.
Miter Lock Knob–The miter lock knob locks the
miter saw table at any desired miter angle.
rotates for desired miter cuts and rotates the
head assembly. The front extended part of the
table is called the miter arm.
Base
workpiece.
saw provide areas to clamp, bolt or nail the saw
to a flat work surface.
provide extra workpiece support and are espe
cially useful when cutting long workpieces.
12
The lever releases the
– Provides working surface to support
8.
-
Getting To Know Your Miter Saw
39
36
27
38
33
40
35
37
34
24
23
31
32
31
22
18. Base Extension Clamping Levers – These
levers lock the base extensions at the 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 a 1-1/4" vacuum hose
hookup.
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 47° right.
23. 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.
24. Slide Rails – Guide the head assembly when
making slide cuts.
25. Quick-Action Clamp Position Holes – There
are two (2) holes (not shown) behind the fence for
placing the quick action clamp.
26. Lower Guard Actuation Link – Allows for
smooth movement of the lower guard.
27. Upper Blade Guard – Covers upper portion of
the blade.
28. Cord Wrap – Allows you to easily wrap up the
cord so it’s out of the way when transporting or
storing.
° to 45° left, 0° to 45° right,
19
29. Power Cord – Supplies power to motor.
30. Hex Wrench – Used for loosening/tightening the
blade and for fence adjustments.
31. 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.
32. Bevel Scale – This scale is large and angled to
allow you to easily read bevel angles.
33. Head Assembly Lock Pin – The saw is
equipped with a lock pin used to lock the head
assembly in the lower position for transporting.
34. Quick Release Depth Stop Button – Allows you
to quickly release the depth stop.
35. Depth Stop Fine Adjustment Knob–Allows you
to adjust the depth of the blade for cutting
grooves in the workpiece (Figure 13, page 16).
Handle Rotation Release Lever
36.
lever allows the handle to be rotated. Release the
lever into one of four operating positions.
37. Rear Carrying Handle – Used for lifting of the
tool.
Handle Clamp –
38.
position.
Arbor Lock
39.
from rotating while tightening or loosening arbor
screw during blade replacement or removal.
40. Front Carrying Handle – Used for lifting the tool.
Arbor Laser / 3x Battery
41.
Locks handle in the selected
—Allows the user to keep the blade
– Pulling this
9.
Assembly
Should be no Gap or Overlap
when Square is Flipped Over in
Dotted Position
Draw Light
Line on Board
Along this Edge
Hex “L” Wrench
(supplied) 1.5mm
Straight Edge of
Board 3/4" Thick
This Edge Must be
Perfectly Straight
Multi Purpose Tool
(supplied)
Combination Square Must be True
Combination Square
10mm/17mm Combination
Open End Wrench
UNLO
CK
LO
CK
Tools Needed For Assembly And Alignment
!
WARNING
!
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.
Model 4412 Miter Saw is shipped complete in one
box.
1. Separate all parts from packing materials and
check each one with the “T
make sure all items are accounted for before discarding any packing material.
2. Table of Loose Parts:
Quick- Action Clamp - Used to clamp workpieces.
Dust Elbow/Dust Bag - Used to collect saw dust.
Multi Purpose
rear base.
Rear Cord Wrap, washer and Screw - Used for
wrapping the cord
Miter Lock Knob - Used to lock the table at desired
miter angle.
Arbor Laser / 3x Battery / Arbor Laser Manual
Disconnect plug from power source before performing any assembly, adjustment or repair to
avoid possible injury.
Unpacking And Checking Contents
Before moving the saw: Lock the
miter lock knob in 45° position. Lock
able of Loose Parts” to
ool - Should be stored on the right
T
!
WARNING
until the missing parts are obtained and are installed
correctly.
Attaching Miter Lock Knob
Locate the miter gauge lock knob from among the
loose parts, and thread shaft on lock knob into hole provided.
Attaching Rear Cord Wrap
Locate the rear cord wrap from among the loose parts,
position rear cord wrap as shown and secure with
washer and phillips screw provided.
Rear Cord Wrap
asher
W
Phillips Screw
If any parts are missing, do not plug
in power cord or turn the switch on
Miter Gauge
Lock Knob
10.
Assembly
Installation And Removal Of The Blade
!
WARNING
adjustment or repair to avoid possible injury.
. The miter saw is equipped with a lock pin used to
1
lock the miter saw in the lower position. To release,
push the handle down slightly and pull the lock pin
to its full out position and rotate 90°.
NOTE:If the lock pin is stuck and will not pull out
when the handle is pushed down slightly, you may
have to adjust the depth stop bolt (see Depth
Adjustment, page 16) slightly so the handle can be
pushed down and the lock pin can be pulled out.
Rotate the lower guard by hand. Loosen front
2.
cover screw to a point that cover plate can be lifted (Figure 1).
3. Rotate the cover plate counterclockwise so the
blade bolt is exposed (Figure 1).
4. Press and hold the arbor lock (See figure on page
9). Use the multi purpose tool to remove the blade
bolt by turning wrench clockwise. NOTE: The
blade bolt has left hand threading.
Cover Plate
Disconnect plug from power source
before performing any assembly,
Lower Guard
Outer Washer
Sawblade
Blade Bolt
(Left Hand Thread)
Inner Washer
Figure 2. Blade Hardware
6. To install the 12" blade, fit blade between the chip
deflectors and onto the arbor shaft, and onto 1"
support ring on the inner washer (Figure 3).
NOTE: Make sure the rotation arrow on the blade
matches the clockwise rotation arrow on the lower
guard.
Front
Cover
Plate
Screw
Rear Cover
Plate Screw
5. Remove the blade bolt, outer washer and the
blade. Inner washer does not need to be removed
(Figure 2).
Upper
Guard
Figure 1. Blade Removal
Blade
Bolt
Outer
Washer
Inner
Washer
Upper
Guard
Figure 3. Blade Installation
!
WARNING
and 1" arbor.
Replace the outer washer in it’
7.
and tighten blade bolt finger tight. Press the arbor
lock and tighten blade bolt securely using multi
purpose tool, but do not overtighten.
Rotate cover plate clockwise to original position.
8.
ighten the front cover plate screw
T
To avoid injury, do not use a blade
larger or smaller than 12" diameter
Arbor
Shaft
s proper orientation,
.
11.
Assembly
!
WARNING
fere with and hang-up lower blade guard.
saw without cover plate securely in place.
guard will not function properly.
9. Be sure the arbor lock is released so the blade
turns freely.
Tighten the cover plate screw.
Loose cover plate screw may inter-
Never use
Lower
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. (Figure 4).
Dust ElbowDust Bag
!
WARNING
interfere with the table insert at the 0° and 45°
bevel positions. Lower the blade into the table slot
and check for any contact with the base or turn table
structure. If blade contacts base or table, seek authorized service.
10. Place multi purpose tool in rubber grommet in right
rear of tool.
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 also accepts a standard 1-1/4"
vacuum tube for dust collection.
After installing a new blade,
make sure the blade does not
Dust
Port
Figure 4. Dust Elbow and Dust Bag
2. Position dust chute/bag so that it does not interfere
with the tool during the cutting operation for all
!
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. Work area should be sealed by plastic
sheeting and persons not protected should be kept
out until work area is thoroughly cleaned.
When sawing chemically pressure
treated lumber, paint that may be
12.
Adjustments
!
WARNING
adjustment or repair to avoid possible injury.
NOTE: Your miter saw was completely adjusted at
he factory. However, during shipment, slight mis-
t
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,
Checking 0° Bevel
Adjustment
1. Push head assembly down and push head assembly lock pin to hold down head assembly.
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 loosen.
5. Check position of bevel range selector knob, it
should be at the 0°-45° position.
6. Tilt the saw assembly to the left counterclockwise.
Then rotate saw assembly to the right (clockwise).
Until you feel the stop in the vertical position – This
is where the saw is currently set for the 0° bevel
cut.
Lower the blade and engage the lock pin. 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 5), follow the
alignment procedure.
Table
Calibrating Blade at 0 degrees
(90° to the table)
1. Lift bevel lock lever to release bevel lock.
. Loosen bolt heads “A” and “B” with 10 mm open-
2
end wrench at least one full turn (Figure 6).
3. Place 4 mm Allen wrench bit onto multi purpose
tool and into setscrew “D” (Figure 6).
4. Loosen setscrew “D” with 4 mm Allen wrench - at
least 3 full turns.
C
A
B
D
Figure 6. Calibrating Blade at 0 degrees
(90 to the table)
5. Place combination square on table and against
fence. (See figure 5)
6. While rotating bolt head “C”, watch the saw blade
tilt until it is aligned with the combination square.
When aligned, remove the Allen wrench.
ighten setscrew “D”.
7. T
8. Tighten 10 mm 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 before cutting.
E
Combination
Square
Figure 5. Blade Square to Table
Bevel Lock
Lever
Blade
Adjusting Bevel Lock Lever Tension
1. Lift bevel lock lever to release bevel lock.
2. Place 17-mm open-end flat wrench on bolt head
“E” (Figure 6).
3. Turn nut “E” clockwise 1/8 turn to tighten bevel
lock tension or turn counter-clockwise to 1/8 turn
to loosen bevel lock tension.
4. Push down bevel lock lever.
erify that bevel lock tension holds the bevel posi-
V
5.
tion secure and also allows bevel lock lever to lock
down to the point that a solid stop is felt.
6. If necessary, repeat steps 1 – 5 to adjust the
tension.
13.
Adjustments
Blade 45° To The Table
Checking 45° Bevel Adjustment
1. Push head assembly down and push head assembly lock pin to hold down head assembly.
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 loosen.
5. Check position of bevel range selector knob, it
should be at the 0°- 45° position.
6. Tilt the saw assembly to the left counterclockwise.
Then rotate saw assembly to the right (clockwise).
Until you feel the stop in the 45° left position – This
is where the saw is currently set for the 45° left
bevel cut.
Blade
Calibrating Blade at 45 degrees to the table
1. Lift bevel lock lever to release bevel lock.
2. Tilt saw head to 45 degree stop on left side.
3. Place combination square frame (remove ruler)
with 45 side against the blade. (See figure 7)
4. Place 10 mm open-end wrench on bolt head “F”
(Figure 8).
5. While rotating bolt “F”, watch blade tilt movement
until it is aligned with the 45 degree surface on
combination square frame.
6. Check and adjust bevel pointers to 45 degrees on
each side of bevel scale.
7. Push down bevel lock lever before cutting.
Combination
Square
Figure 7. Blade 45° To The Table
Use a head of 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 5), follow the alignment procedure.
Table
Bevel Lock
Lever
F
Figure 8. Calibrating Blade at 45 degrees
to the table
14.
Adjustments
15
10
5
20
25
30
0
35
0
2
12
4
12
6
12
8
12
55
50
45
60
40
Blade Square to Fence
1. Make sure head assembly is pushed forward
ear the center of the table and slide rail lock
n
nob is tightened.
k
2. Lower the head assembly, pull the lock pin out and
rotate it 90°, rotate to lock the head assembly in the
down position. Make sure table is in 0°
detent and tighten miter lock knob. 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 9).
3. If blade does not contact the square, follow the
fence alignment procedure.
Fence
Blade
Fence alignment
a. Remove sliding fence extensions.
b. The head assembly should remain in lowered
position.
c. Use multi purpose wrench (supplied) and
loosen four (4) hex bolts behind fence
(Figure 10).
d. Adjust fence until blade and the fence has full
contact with the square.
e. Tighten hex bolts.
f. Re-attach sliding fence.
Hex Bolts
Figure 10. Fence Adjustment
Combination Square
Figure 9. 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 11).
Position the indicator to align with the 0
4.
mark.
T
ighten the screw.
° miter
0° Mark
Miter Scale
Indicator
Figure 11. Miter Scale Adjustment
Indicator
Adjustment
Screw
15.
Adjustments
15
10
5
2
0
2
5
3
0
0
5
0
2
1
2
4
12
6
1
2
1
2
55
50
45
60
40
Kerf Insert
The kerf insert should be adjusted close to the blade,
but without touching the blade, to avoid tear-out 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-
pose tool (Figure 12).
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.
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 27 for
cutting grooves.)
Loosen and turn both Jam Nuts to just above the
1.
threaded end of the Depth Stop Bolt (Figure 13).
Depth Stop
Bolt
Depth Stop
Jam Nuts
Release Button
Kerf
Screws
Kerf
Inserts
Figure 12. Kerf Insert
3. Set the table to the 0° miter position. Push down
and slide back saw head to the full back position.
4. While looking at both the blade and the corner
where the fence meets the table, turn the Depth
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.
6. Turn both Jam Nuts to be tight against the bottom
of the support frame. Tighten nuts against each
other.
Practice slide cutting (with tool unplugged) to veri
7.
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
!
CAUTION
Do not start the miter saw without
checking for interference between
the blade and the turn table structure. The blade
could be ruined if it cuts into the table structure.
-
Setting Blade Depth for Cutting Grooves
Figure 13. Depth Adjustment
2. Press Depth Stop Release Button and pull up
Depth Stop Bolt until nuts hit the bottom of its
support frame (Figure 13).
The depth stop can be easily adjusted to limit the
cutting depth, such as when creating a rough slot.
(See page 27 for instructions)
16.
Transporting, Placement and 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
f it’s rail, tighten the slide rail lock knob and lock
o
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 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
nd the wire connections resulting in electric shock
a
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
Workbench
Mount the saw using either the four bolt holes (5/16")
or the four nail holes to the workbench (Figure 14).
Check for clearance to the left and right of the saw.
Rear Carrying
Handle
Front Carrying
Handle
Bolt Hole
Nail Hole
1. Each of the four mounting holes should be bolted
securely using 5/16" bolts, lock washers, and hex
nuts (not included).
2. Locate and mark where the saw is to be mounted.
3. Drill four (4) 5/16" diameter holes through workbench.
4. Place the miter saw on the workbench aligning
holes in base with holes drilled in workbench.
Install bolts, lock washers and hex nuts. As an
alternative, you can mount the saw using drywall
screws in the four nail holes.
Supporting surface where saw is to be mounted
should be examined carefully after mounting to
ensure that no movement can occur during use. If
any tipping or walking is noted, secure the work
bench or stand before operating the slide com
pound miter saw.
-
-
Figure 14. Workbench Mounting
17.
Mounting the Saw
Pullto
Rota
te
Ha
ndle
P
ul
l
t
o
R
ot
a
t
e
H
a
ndl
e
Pullto Rotate Handle
Pullto Rotate Handle
Portable Mounting Using Clamps
f necessary, clamp the miter saw to a workbench
● I
or table top.
lace two (2) or more “C” clamps on the clamping
● P
areas and secure (Figure 15).
● Be careful not to place clamps over the base
extension clamping levers (Figure 15).
● Mounting with clamps will prevent access to some
wide miter angles.
Clamping
Areas
Clamping Areas
Figure 15. Portable Mounting Using Clamps
Adjusting the Four Position
Switch Handle
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.
● vertical
● horizontal
Left
● 45°
● 45° Right
o reposition the main handle:
T
1. Release handle clamp (Figure 16).
2. Pull and hold handle rotation release lever
(Figure 16).
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.
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. Always adjust both
setscrews by the same amount.
3. Close handle clamp.
4. Check the tension.
Handle
Clamp
Handle Rotation
Release Lever
Adjusting the Four-Position Handle
1. Open handle clamp.
Clamp Tension
Figure 16. Setting Main Handle Position
18.
Basic Saw Operations
Body and Hand Position
!
WARNING
safer. Observe the following instructions (Figure 17).
Correct
● 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 boundry. 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.
DR
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.
Position your body and hands properly to make cutting easier and
Incorrect Use
Projected Line Of Cut
Figure 17. Hand Positions
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 18).
● 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
orkpiece
W
19.
Figure 18. Raising Lower Guard
Basic Saw Operations
Workpiece Support
ong workpieces have a tendency to
!
WARNING
roperly supported from underneath.
p
Quick-Action Clamp - This clamp easily secures a
workpiece in either of two (2) clamp holes behind the
fence (Figure 19).
● 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.
L
tip over unless clamped down and
Clamps
There may be extreme compound
cuts where clamp cannot be used.
Long workpiece support
Sliding Base Extensions – These extensions pro-
vide extra workpiece support and are especially useful when cutting long workpieces. To reposition the
xtensions, simply unlock the Base Extension
e
Clamping Levers, reposition the extensions, and relock the levers (Figure 20). (See also Length Stop on
page 27.)
Extra-Long Base Extension Rods – The optional
MS1222 Base Extension Kit allow the 4412’s base
extensions to extend out to 60”. Even after these
longer rods are installed on the 4412, the base extensions can be fully retracted for transportation and
storage.
Sliding
Base
Extensions
Quick-Action
Clamp
Clamp
Clamp
Post
Clamp
Hole
Screw Rod
Figure 19. Quick-Action Clamp
Horizontal Clamp –
Clamp and crown stop 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.
The optional MS1221 Horizontal
Hole
Clamp Levers
Figure 20. Sliding Base Extensions
Blocks - Long pieces need extra support. The base
height (3-3/4") is designed to match the standard
lumber of two 2x’s and one 1x. Boards of these thicknesses can be used to create auxiliary support extensions for long workpieces (Figure 21).
Two 2x’s
and One 1x’s
20.
Figure 21. Block Support
Basic Saw Operations
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
° bevel position only
0
1. Place a piece of wood against the miter saw fence
(Figure 22). (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 screws wood screws (3/4" long). Drill four (4)
smaller (then 1/4
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
.
" pilot holes through auxiliary
and the lower blade guard. Make adjustments as
necessary.
heck for interference from any
!
WARNING
Auxiliary
Fence
C
components.
lade Slot
B
Flat Head
Machine Screws
Figure 22. Auxiliary Fence
Switch Activation
For safety
accidental starts.
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
(Figure 23). When the power switch lever is released,
the switch “Lock-OFF” button will engage the safety
switch automatically
operate until either “Lock-Of
again.
NOTE: Switch lever can accommodate a padlock
with a long shackle of up to 1/4" in diameter (not
provided with miter saw to prevent unauthorized use.
, the switch lever is designed to prevent
o operate safety switch, press the
T
, and the lever will no longer
f” button is pressed
Power
Switch Lever
Switch
“Lock-Off”
Release Button
Figure 23. Switch Activation
21.
Basic Saw Operations
15
10
5
20
0
0
2
12
55
50
45
60
40
Miter Detent Override
The miter detent override feature allows the detent
ction to be locked out, allowing for micro adjust-
a
ments at any miter angle. When the desired miter
ngle is to close to a standard mitering angle that has
a
a detent slot, this feature prevents the wedge on the
miter arm from slipping into the detent slot on the
base.
1. Lift and hold the miter detent lever (under base
arm).
2. Push the detent override clip forward and latch in
place over edge. Release miter detent lever
(Figure 24).
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
lever to release the detent override clip. The clip
should automatically disengage and the table
should lock into any desired miter detent.
Clip Edge
Override Clip
Miter
Detent Lever
Figure 24. Detent Override
Detent
Miter
Lock Knob
Sliding Fences and Base Extensions
!
WARNING
So as to provide sufficient (mini-
mum 6”) spacing from hand to saw
blade, extend the sliding fences and base extensions
when making extreme bevel, miter or compound
cuts.
The base extensions can also be used to provide
extra support for long workpieces.
Sliding Base:
1. Loosen the base extension clamping levers
(Figure 25).
2. Extend sliding base extensions to the desired
position.
Press the levers down to clamp the extensions
3.
into place.
1. Loosen the fence locking knobs (behind fence).
2. Slide fence to proper position.
3. T
ighten knobs to lock fence into place.
Sliding Fence:
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 centermost position.
3. Lift fence to remove.
4. Tighten knob
After the cut is complete, reinstall the sliding fence.
To reinstall the sliding fence, reverse this procedure.
!
CAUTION
During transportation, sliding base
extensions and fences should
always be secured in the fully closed position.
Sliding Fences
and Base
Extensions
Base Extensions
Clamping levers
Figure 25. Sliding Fences and Base Extensions
See page 20 for information about other types of
workpiece support.
22.
Saw Operations
Chop Cut
● The slide rail lock knob is tightened and the head
ssembly is lowered to cut through the workpiece.
a
● 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 (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.
!
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
Figure 26. 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.
3. Grasp the switch handle and pull the head assembly
away from the fence, until the blade clears the workpiece or to its maximum extension if blade cannot
clear the workpiece (Figure
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
27).
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 27. Slide Cut
23.
Saw Operations
Miter Cut
●
“miter cut” is a cross-cut made with the blade ver-
A
tical (non-tilted) at a horizontal angle relative to the
fence.
● A miter cut is made at 0° bevel and any miter angle
in the range from 52° left to 60° right.
● The miter scale shows the angle of the blade
relative to the fence angle is cast-in on the table for
easy reading.
● Positive detents have been provided for fast and
accurate mitering at 0°, 15°, 22.5°, 31.6°
and 45° left and right and 60° right.
● The crown molding detents (left and right) are at
31.6° (See Cutting Crown Molding for more information page 29).
● For precision settings at angles next to the
detents, use the detent override to lock out the
detent. This prevents the wedge on the detent
lever from slipping back into the detent.
● 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).
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 (Figure 28).
2. Extend the base extensions and fence on the side
on which the cut will be made. (See Sliding Fence
and Base Extension on page 22).
3. Properly position workpiece. Make sure workpiece is clamped firmly against the table or the
fence.
!
WARNING
Use clamping position that does not
interfere with operation. Before
switching on, lower head assembly to make sure
clamp clears guard and head assembly.
4. Follow procedures for either chop cut or slide cut
(see page 23).
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
Miter
Scale
Detents
Miter Lock
Knob
Figure 28. Miter Cut
Bevel Cut
● A “bevel cut” is a cross-cut made with the blade
perpendicular to the fence but tilted away from the
vertical position.
● A bevel cut is made at 0° miter and any bevel angle
.
°
to 47
in the range of -47
● The bevel scale is sized and positioned for easy
reading.
● The front-positioned bevel range selector knob
provides three bevel range choices.
● There are factory set bevel stops at 0
both the left and right. (See Adjustment section if
adjustments are required.)
● There are also positive crown molding bevel
stops at 33.9° on both the left and right.
°
on
and 45
°
°
Disengage this stop unless using the 33.9°
angle (See Cutting Crown Molding for details.)
bevel cut can be made as either a chop cut or a
● 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.
1. Lift the bevel lock lever to unlock. Choose the
desired bevel range using the bevel range selector
knob. If in the 0° position and moving to the 0°-to-
right range or 47
°
45
°
range, it may be nec
°
-to-47
essary to move the head assembly slightly to the
left before the bevel range selector knob can be
turned.
Applying pressure to the cutting assembly
may not allow you to move the bevel range selector Knob.
24.
-
evel Range 1 = 45° Left to 0°
UNLOCK
LOCK
00
44 --55
Left
00 44-- 55
Right
44 --77 4477
Max
0-45º
0-45º
B
This left side bevel range is the default setting
T
o operate in range 1:
1. Move the left sliding fence to clear saw
assembly and re-lock (Figure 29).
2. Lift bevel lock lever to the table height
ith the left hand (Figure 30).
w
3. Grasp the front carry handle with the
right hand and tilt saw head to angle
desired.
4. Once in the desired bevel position, fully press
down bevel lock lever below table height
(Figure 29)..
Without turning the saw on, practice the cutting
action to make sure the fence clears the guards and
adjust as necessary.
Bevel Range 2 = 0° to 45° Right
To operate in range 2:
1. Move right sliding fence to clear saw
assembly and re-lock (Figure 29).
2. Lift bevel lock lever to the table height
with the left hand (Figure 30).
3. Grasp the front carry handle with the left hand and
tilt saw head slightly to the left while rotating the
spring-loaded bevel range selector knob with the
right hand so the symbol “ 45-0° “ lines up with the
arrow on the table (Figure 31). The saw assembly
may now be tilted to a right bevel angle up to the
45° stop.
4. Once in the desired bevel position press down
bevel lock lever below table height.
NOTE: When the saw assembly is tilted back left
past 0°, the bevel control knob will snap back to the
default bevel range 1. This is designed to regain the
pre-set bevel stop at the important 0° position.
Bevel Range 3 = 47° Left to 47° Right
This full capacity bevel range setting overrides all
preset stops and allows for cutting at bevel angles
beyond the normal 45° on either side.
To operate in range 3:
Move left and right-sliding fences to
1.
clear saw assembly and re-lock
(Figure 29).
2. Lift bevel lock lever to the table height
with the left hand (Figure 30).
3. Grasp the front carry handle with the left hand and
tilt saw head slightly to the left while rotating the
spring-loaded bevel range selector knob with the
right hand so the symbol “ 47-47° “ lines up with
the arrow on the table (Figure 31). The saw
assembly may now be tilted to any angle from 47
left to 47°right.
. Once in the desired bevel position, fully press
4
down bevel lock lever below table height.
Follow these instructions for
making your bevel cut:
5. Extend the base extensions and fence on the side
on which the cut will be made. (See Sliding Fence
nd Base Extension on page 22).
a
6. Properly position workpiece. Make sure work
piece is clamped firmly against the table and the
fence.
!
WARNING
switching on, lower head assembly to make sure
clamp clears guard and head assembly.
7. Follow the procedures for either a chop cut or slide
cut (see page 23).
8. Wait until blade comes to a complete stop before
returning head assembly to the raised position
and/or removing workpiece.
Front Carry
Handle
Sliding
Fence
°
Use clamping position that does not
interfere with operation. Before
Figure 29.
Bevel Lock
Lever
Figure 30.
Bevel Range Selector Knob
Figure 31.
25.
Saw Operations
Compound Cuts
● A “compound cut” is a cross-cut made with the
lade both at a horizontal angle relative to the
b
ence (at a miter angle) and tilted away from the
f
vertical position (at a 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 22.)
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.
3. Set miter and bevel angles according to the
instructions on page 24 and 25 for miter and bevel
cuts.
4. Follow the procedures for either chop cut or slide
cut (see page 23).
Use clamping position that does not
interfere with operation. Before
5. Wait until blade comes to a complete stop before
eturning head assembly to the raised position
r
nd / or removing workpiece.
a
Quick-Action
Clamp
Workpiece
Sliding
Base
Bevel Angle
Scale
Figure 32. Compound Cut
Miter
Angle
26.
Saw Operations
Cutting Grooves
● The depth stop adjustment is a feature used when
utting grooves in the workpiece.
c
● The depth adjustment is used to limit blade depth
o cut grooves.
t
● 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 33).
2. For minor adjustments, simply rotate the depth
stop bolt to the desired location.
Depth Stop
Bolt
Depth Stop
Jam Nuts
Figure 33. Cutting Grooves
Release Button
3. Cut the two outside grooves.
4. Use a wood chisel or make multiple passes by
sliding the wood over to one side to remove the
aterial between the outside grooves (Figure 33a).
m
Outside Grooves
Workpiece
Figure 33a. Rough Cut Groove
Chisel Cut
Length Stop
The unit’s flip up length stop can be used when
making repetitive cuts of the same length.
To set the stop, simply unscrew the knob, flip the stop
into position and tighten the knob (Figure 34).
1. To set the cut length, unlock the base extension
clamping lever, reposition the base extension and
length stop, and relock the levers.
The maximum length that can be cut using the
2.
length stop is approximately 20".
If desired, the length stop and knob can be moved to
the left base extension. The optional MS1223 Length
Stop Kit can also be installed on the left side to provide stops on either side of the saw.
o increase the length that can be cut using the
T
length stop, replace the tool’s base extension rods
with the optional MS1222 Extra-Long Base Rod Kit ,
which increases the maximum length that can be cut
using the length stop to approximately 30” on either
side of the tool.
Length Stop
Figure 34. Length Stop
Knob
27.
Saw Operations
Left
Right
Left
Right
Cutting Base Molding
ase molding can be cut vertical against fence or
● B
flat on the table. The maximum size that can be
vertical on the fence is 4-1/4", flat on table is
10-1/4".
ollow the table for helpful hints on cutting base
● F
molding for corners that have 90° angles.
utting base molding can be done either as a chop
● C
cut or a slide cut depending on the size of the workpiece.
BASE MOLDING CUTTING INSTRUCTIONS
LOCATION OF Molding in Vertical Position: Molding in Horizontal Position:
MOLDING Back of molding is Back of molding is flat
ON SAW against the fence on the table
Bevel Angle Bevel = 0° Bevel = 45°
Molding Piece Being Cut To left of corner To right of corner To left of corner To right of corner
Inside Miter Angle Left at 45° Right at 45° 0° 0°
corner of wall
Position of Bottom Bottom Top against Bottom
molding on Saw against table against table fence against fence
Finished Keep left Keep right Keep left Keep left
side side of cut side of cut side of cut side of cut
Outside Miter Angle Right at 45° Left at 45° 0° 0°
corner of wall
Position of Bottom Bottom Bottom against Top against
molding on Saw against table against table fence fence
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
properly to fit exactly.
● There are two ways to cut crown molding: flat on
table or angled to table and fence.
● Crown molding’
between the back of the molding and the bottom
flat surface that fits against the wall.
● This miter saw has special miter detents at
31.6
detents allow you to easily position most crown
moldings flat on the table and make precise cuts
for 90° corners. (These detents are only for use
with crown moldings that have a 38° “spring
angle”.) NOTE: These detents cannot be
used with 45° crown molding.
molding must be cuts must be positioned
s “spring angle” is the angle
and bevel detents at 33.9°. These
°
● See also pages 29 & 30 for miter and bevel angle
charts for cutting crown moldings that have
38° and 45° spring angles (and the material is
laid flat on the miter saw base). Each chart lists the
exact miter and bevel settings required for a wide
range of corner angles.
● Even though these angles are standards, most
rooms do not have angles of exactly 90°, therefore, you will need to fine tune your settings.
The optional Bosch DWM40L MiterFinder
Digital
angles and corner angles, then automatically deter
mines the exact miter and bevel settings
necessary to make each crown molding cut fit
perfectly
Anglefinder/Protractor measures spring
.
-
28.
Saw Operations
Crown Molding Laying Flat on Table
otes:Position workpiece with its back flat on the
● N
saw table.
● Always place top edge of molding against fence
(Decorative edge is at the bottom of crown mold-
ng.)
i
● "Spring angle" refers to angle between wall and
crown molding.
● Cutting crown molding flat on the table can be done
either as a chop cut or a slide cut depending on the
width of the workpiece.
1. For 90º corner, set the bevel and miter angles
using Charts below. Tighten the miter lock knob
and the bevel lock lever (Figure 35).
2. Position molding on saw table. Clamp workpiece
in place using the quick clamp.
!
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 23).
4. Wait until blade comes to a complete stop before
returning head assembly to the raised position
and/or removing workpiece.
NOTE: ALWAYS TAKE A TEST CUT USING
SCRAP TO CONFIRM CORRECT ANGLES.
Use clamping position that does not
interfere with operation. Before
Quick-Action
Clamp
Crown
Molding
33.9° Bevel
31.6° Miter
Figure 35. Crown Molding Laying Flat
Miter and Bevel Settings for Standard Crown Molding Cuts
(When Crown Molding is Lying Flat on Table)
Assumptions: Molding is milled consistently. Corner is exactly 90º.
Molding Spring Angle is 38 degrees
Miter Bevel
(Table) (Tilt)
Setting Setting
Inside Corner
Left end (A) (31.6) Right (33.9) Left
Use the left end of the cut
Right end (B)
Use the right end of the cut
Outside Corner
Left end (C)
Use the left end of the cut
Right end (D)
Use the right end of the cut
(31.6) Left (33.9) Right
(31.6) Left (33.9) Right
(31.6) Right
(33.9) Left
Molding Spring Angle is 45 degrees
Miter Bevel
(Table) (Tilt)
Setting Setting
Inside Corner
Left end (A) (35.3) Right (30.0) Left
Use the left end of the cut
Right end (B)
Use the right end of the cut
Outside Corner
Left end (C)
Use the left end of the cut
Right end (D)
Use the right end of the cut
(35.3) Left (30.0) Right
(35.3) Left (30.0) Right
(35.3) Right
(30.0) Left
29.
Saw Operations
Crown Molding Angled to Table and Fence
he preferred method for cutting crown molding with
T
this saw is with the molding laying flat on the table.
● The advantage to cutting moldings angled against
fence is that no bevel setting is required. Only the
miter angle is adjusted.
● The maximum crown molding width that can be
cut and angled to table and fence is 6".
● When cutting crown molding in this fashion it is
recommended to purchase and use the optional
MS 1221 Horizontal Clamp and Crown Molding
Stop Accessory.
Follow these instructions for cutting
crown molding angled to table and fence.
1. Position the molding so the bottom (decorative
part, which is installed against the wall) is against
the fence.
2. For 90º corner, set the miter angle using Chart
below. Tighten the miter lock knob (Figure 36).
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 23).
5. Wait until blade comes to a complete stop before
returning head assembly to the raised position
and/or removing workpiece.
OTE: ALWAYS TAKE A TEST CUT USING
N
SCRAP TO CONFIRM CORRECT ANGLES.
Crown Molding
Angled Against Fence
45º Miter
Figure 36. Crown Molding Angled to
Table and Fence
Miter and Bevel Settings for Standard Crown Molding Cuts
(When Workpiece Angled Against Fence)
Assumptions: Molding is milled consistently
● Corner is 90 degrees.
● For other corner angles, divide actual measure-
ment by 2.
.
For any Crown Molding
Miter Bevel
(Table) (Tilt)
Setting Setting
Inside Corner
Left end (A) (45) Right 0 Left
Use the right end of the cut
Right end (B) (45) Left 0 Right
Use the left end of the cut
Outside Corner
Left end (C) (45) Left 0 Right
Use the right end of the cut
Right end (D) (45) Right 0 Left
Use the left end of the cut
30.
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