IMPORTANT: |
IMPORTANTE: |
IMPORTANT : |
Read Before Using |
Leer antes de usar |
Lire avant usage |
|
|
|
Operating/Safety Instructions
Instrucciones de funcionamiento y seguridad Consignes de fonctionnement/sécurité
5412L
|
Call Toll Free |
Llame gratis para |
Pour renseignement des |
|
|
for Consumer Information |
obtener información |
consommateurs et centres |
|
|
& Service Locations |
para el consumidor y |
de service, appelez au |
|
|
|
ubicaciones de servicio |
numéro gratuit : |
|
|
|
|||
|
1-877-BOSCH99 (1-877-267-2499) www.boschtools.com |
|
||
|
|
|
|
|
|
|
|
|
|
For English |
¿Habla español? |
Parlez-vous français? |
||
See page 2 |
Ver página 38 |
Voir page 74 |
||
|
|
|
|
|
|
|
Safety |
|
|
|
“READ ALL INSTRUCTIONS” — Failure to follow the SAFETY RULES identified by |
|
|
! WARNING |
||
|
BULLET (●) symbol listed BELOW and other safety precautions, may result in serious person- |
||
al injury. |
|||
|
|||
|
|
|
|
General Safety Rules
For Bench Top Tools
Work Area
●Keep work area clean and well lit. Cluttered benches and dark areas invite accidents.
●Do not operate power tools in explosive atmospheres, such as in the presence of flammable liquids, gases or dust. Power tools create sparks which may ignite the dust or fumes.
●Keep bystanders, children and visitors away while operating a power tool. Distractions can cause you to lose control.
●Store idle tools out of reach of children and other untrained persons. Tools are dangerous in the hands of untrained users.
●Do not leave tool running unattended, turn power off. Do not leave tool until it comes to a complete stop.
●MAKE WORKSHOP CHILDPROOF with pad lock, master switches, or by removing starter keys.
Electrical Safety
●Before plugging in the tool, be certain the outlet voltage supplied is compatible with the voltage marked on the nameplate within 10%. An outlet voltage incompatible with that specified on the nameplate can result in serious hazards and damage to the tool.
●Double insulated tools are equipped with a polarized plug (one blade is wider than the other). This plug will fit in a polarized outlet only one way. If the plug does not fit fully in the outlet, reverse the plug. If it still does not fit, contact a qualified electrician to install a polarized outlet. Do not change the plug in any way. Double insulation eliminates the need for the three wire grounded power cord and grounded power supply.
●Avoid body contact with grounded surfaces such as pipes, radiators, ranges and refrigerators. There is an increased risk of electric shock if your body is grounded.
●Do not expose power tools to rain or wet conditions. Water entering a power tool will increase the risk of electric shock.
●Do not abuse the cord. Never use the cord to carry the tools or pull the plug from an outlet. Keep cord away from heat, oil, sharp edges or moving parts. Replace damaged cords immediately. Damaged cords increase the risk of electric shock.
●When operating a power tool outside, use an outdoor extension cord marked “W-A” or “W”. These cords are rated for outdoor use and reduce the risk of electric shock.
Personal Safety
●Stay alert, watch what you are doing and use common sense when operating a power tool. A moment of inattention or use of drugs, alcohol or medication while operating power tools can be dangerous.
●Dress properly. Do not wear loose clothing or jewelry. Contain long hair. Keep your hair, clothing and gloves away from moving parts. Loose clothes, jewelry or long hair can be caught in moving parts. Roll long sleeves above elbows. Rubber gloves and non-skid footwear are recommended when working outdoors.
●Avoid accidental starting. Be sure switch is “OFF” before plugging in. Carrying tools with your finger on the switch or plugging in tools that have the switch “ON” invites accidents.
●Remove adjusting keys or wrenches before turning the tool “ON”. A wrench or a key that is left attached to a rotating part of the tool will be thrown.
●Do not overreach, keep proper footing and balance at all times. Proper footing and balance enables better control of the tool in unexpected situations.
●Do not stand on tool or its stand. Serious injury may occur if the tool is tipped or if the cutting tool is accidentally contacted. Do not store materials on or near the tool such that it is necessary to stand on the tool or its stand to reach them.
“SAVE THESE INSTRUCTIONS”
2.
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 person-
al injury.
●Use safety equipment. Always wear safety goggles. Dust mask, safety shoes, hard hat or hearing protection must be used for appropriate conditions. Everyday eyeglasses only have impact resistant lenses, they are NOT safety glasses.
Tool Use and Care
●Use clamps or other practical way to secure and support the workpiece to a stable platform. Holding the work by hand or against your body is unstable. It allows for work to shift, causes binding of the tool and loss of control.
●Do not force tool. Use the correct tool for your application. The correct tool will do the job better and safer at the rate for which it is designed. Do not use the tool for purpose not intended - for example; do not use the miter saw for slicing meats.
●Do not use tool if switch does not turn it “ON” or “OFF”. Any tool that cannot be controlled with the switch is dangerous.
●Disconnect the plug from the power source before making any adjustments or changing accessories. Such preventive safety measures reduce the risk of starting the tool accidentally.
●Keep cutting tools sharp and clean. Properly maintained tools, with sharp cutting edges, are less likely to bind and easier to control. When mounting saw blades be certain that the arrow on the blade matches the direction of the arrow marked on the tool and that the teeth are also pointing in the same direction.
●Inspect guards before using a tool. Keep guards in place. Check moving parts for binding or any other condition that may affect the normal operation or safety features of the tool. If damaged, have tool serviced before using the tool. Many accidents are caused by poorly maintained tools.
●Do not alter or misuse tool. Any alteration or modification is a misuse and may result in serious personal injury.
●The use of any other accessories not specified in this manual may create a hazard.
Accessories that may be suitable for one type of tool, may become hazardous when used on an inappropriate tool.
Service
●Tool service must be performed only by qualified repair personnel. Service or maintenance performed by unqualified personnel may result in misplacing internal wires and components which could cause serious hazard.
●When servicing a tool, use only identical replacement parts. Follow instructions in the Maintenance section of this manual. Use of unauthorized parts or failure to follow Maintenance Instructions may create a hazard.
Safety Rules
For Miter Saws
●Use clamps to support workpiece whenever possible. If supporting the workpiece by hand, you must always keep hand outside of “No Hand” area as marked with a symbol on the base. Do not use this saw to cut pieces that are too small to be securely clamped.
Your hand if placed inside the “No Hands” region can easily slip or be pulled into the blade.
●Do not reach in back of the saw blade behind the fence with either hand to hold down or support the workpiece, remove wood scraps, or for any other reason. The proximity of the spinning saw blade to your hand may not be obvious and you may be seriously injured.
●Never cross your hand over intended line of cutting. Supporting the workpiece “cross handed” i.e. holding the left side of the workpiece with your right hand is very dangerous.
●Always disconnect the power cord from the power source before making any adjustments or attaching any accessories. You may unintentionally start the saw, leading to serious personal injury.
●Miter saws are intended to cut wood or woodlike products, they cannot be used with abrasive cutoff wheels for cutting ferrous material such as bars, rods, studs, etc. However, if cutting materials like aluminum or other non-ferrous metals, use only saw blades specifically recommended for nonferrous metal cutting. Cutting ferrous materials causes excessive sparking and will damage the lower guard and will overload the motor. (NOTE: Robert Bosch Tool Corporation doe not offer 12” metal cutting blades.)
“SAVE THESE INSTRUCTIONS”
3.
Safety
! WARNING “READ ALL INSTRUCTIONS” — Failure to follow the SAFETY RULES identified by BULLET (●) symbol listed BELOW and other safety precautions, may result in serious person-
al injury.
●Inspect your workpiece before cutting. If workpiece is bowed or warped, clamp it with the outside bowed face toward the fence. Always make certain that there is no gap between the workpiece, fence and table along the line of the cut. Bent or warped workpieces can twist or rock and may cause binding on the spinning saw blade while cutting. Also, make sure there are no nails or foreign objects in the workpiece.
●Do not use the saw until the table is clear of all tools, wood scraps, etc., except the workpiece. Small debris or loose pieces of wood or other objects that contact the revolving blade can be thrown with high speed at the operator.
●Do not feed workpiece into the blade or cut “freehand” in any way. Workpiece must be stationary and clamped or braced by your hand. Saw must be fed through the workpiece smoothly and at a rate which will not overload the saw’s motor.
●Cut only one workpiece at a time. Multiple workpieces cannot be adequately clamped or braced and may bind on the blade or shift during cutting.
●Be certain the miter saw is mounted or placed on a level, firm work surface before using. A level and firm work surface reduces the risk of the miter saw becoming unstable.
●Plan your work. Provide adequate support accessories such as tables, saw horses, table extension, etc. for workpieces wider or longer than the table top (see page 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 contacting the workpiece. This will help avoid thrown workpieces.
●If the workpiece or blade becomes jammed or bogged down, turn miter saw “OFF” by releasing switch. Wait for all moving parts to stop and unplug the miter saw, then work to free the jammed material. Continued sawing with jammed workpiece could cause loss of control or damage to miter saw.
●Braking action of the saw causes the saw head to jerk downward. Be ready for this reaction when making an incomplete cut or when releasing the switch before the head is completely in the down position.
●After finishing the cut, release the switch, hold the saw arm down and wait for blade to stop before removing work or cutoff piece. If blade does not stop within five (5) seconds, unplug the saw and follow the instructions in the Troubleshooting section.
REACHING WITH YOUR HAND UNDER A COASTING BLADE IS DANGEROUS!
●There are additional safety instructions for particular operations of the saw in the operating section. Read the rest of the manual for safe operation.
●For 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
! WARNING “READ ALL INSTRUCTIONS” — Failure to follow the SAFETY RULES identified by BULLET (●) symbol listed BELOW and other safety precautions, may result in serious personal
injury.
●Do not allow familiarity gained from frequent use of your miter saw to become commonplace. Always remember that a careless fraction of a second is sufficient to inflict severe injury.
●THINK SAFETY! SAFETY IS A COMBINATION OF OPERATOR’S COMMON SENSE, KNOWLEDGE OF THE SAFETY AND OPERATING INSTRUCTIONS AND ALERTNESS AT ALL TIMES WHEN THE MITER SAW IS BEING USED.
THE WARNINGS SHOWN
BELOW CAN BE FOUND ON YOUR TOOL. THESE WARNINGS ARE ONLY A CONDENSED FORM OF THE MORE DETAILED SAFETY RULES AND PRECAUTIONS THAT APPEAR IN YOUR OWNER'S MANUAL. THEY SERVE AS A REMINDER OF ALL SAFETY RULES NEEDED FOR SAFE OPERATION OF THIS MITER SAW.
! WARNING Some dust created by power sanding, sawing, grinding,
drilling, and other construction activities contains chemicals known to cause cancer, birth defects or other reproductive harm. Some examples of these chemicals are:
•Lead from lead-based paints,
•Crystalline silica from bricks and cement and other masonry products, and
•Arsenic and chromium from chemically treated lumber.
Your risk from these exposures varies, depending on how often you do this type of work. To reduce your exposure to these chemicals: work in a well ventilated area, and work with approved safety equipment, such as those dust masks that are specially designed to filter out microscopic particles.
DESIGNATED DANGER ZONE. AVOID POSITIONING HANDS, FINGERS OR ARMS IN THE AREA DESIGNATED BY THIS SYMBOL.
“SAVE THESE INSTRUCTIONS”
5.
Safety
! WARNING |
“READ ALL INSTRUCTIONS” |
— Failure to follow the SAFETY RULES identified by |
|
BULLET (●) symbol listed BELOW and other safety precautions, may result in serious personal |
|||
injury. |
|||
|
|
||
Double Insulated Tools |
Extension Cords |
||
Double insulation 
is a design concept used in electric power tools which eliminates the need for the three wire grounded power cord and grounded power supply system. It is a recognized and approved system by Underwriter’s Laboratories, CSA and Federal OSHA authorities.
●Servicing of a tool with double insulation requires care and knowledge of the system and should be performed only by a qualified service technician.
●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.
●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.
RECOMMENDED SIZES OF EXTENSION CORDS
Tools |
|
120 Volt A.C. Tools |
|
|
Ampere |
|
Cord Length in Feet |
|
|
Rating |
|
Cord Size in A.W.G. |
|
|
|
|
|
|
|
|
25 |
50 |
100 |
150 |
|
|
|
|
|
3-6 |
18 |
16 |
16 |
14 |
6-8 |
18 |
16 |
14 |
12 |
8-10 |
18 |
16 |
14 |
12 |
10-12 |
16 |
16 |
14 |
12 |
12-16 |
14 |
12 |
N/A |
N/A |
|
|
|
|
|
NOTE: The smaller the gauge number, the heavier the cord.
“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. . . . . . . . . . . . . . . . . . . . 7 Getting To Know Your Miter Saw. . . . . . . . . . . 8-9
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-12 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. . . . . . . 12
Adjustments. . . . . . . . . . . . . . . . . . . . . . . . . . 13-16 Checking 0° Bevel Adjustment . . . . . . . . . . . . . 13 Adjusting Bevel Lock Lever Tension. . . . . . . . . 13 Blade 45° To The Table . . . . . . . . . . . . . . . . . . 14 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 . . . . . . . . . . . . . . . . . . . . . . . 18
Adjusting the Four Position Switch Handle . . . 18
Basic Saw Operations . . . . . . . . . . . . . . . . . 19-22
Body and Hand Position. . . . . . . . . . . . . . . . . . 19
Workpiece Support . . . . . . . . . . . . . . . . . . . 20-21
Switch Activation. . . . . . . . . . . . . . . . . . . . . . . . 21
Detent Override . . . . . . . . . . . . . . . . . . . . . . . . 22
Sliding Base/Fence Extension . . . . . . . . . . . . . 22
Saw Operations . . . . . . . . . . . . . . . . . . . . . . . 23-30
Chop Cut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Slide Cut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Miter Cut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Bevel Cut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Compound Cuts . . . . . . . . . . . . . . . . . . . . . . . . 26
Cutting Grooves . . . . . . . . . . . . . . . . . . . . . . . 27
Cutting Base Molding . . . . . . . . . . . . . . . . . . . . 28
Cutting Crown Molding . . . . . . . . . . . . . . . . 28-30
Special Cuts . . . . . . . . . . . . . . . . . . . . . . . . 31-33
Maintenance and Lubrication . . . . . . . . . . . 34-35
Belt Changes. . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . 35-36
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
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 When electrical power is lost due to blown fuse or other causes, the
motor will gradually slow down and the braking action is initiated ONLY by the release of the trigger switch.
The electric blade brake of your miter saw has been designed for highest degree of reliability, but unexpected circumstances such as contamination on the commutator and brushes or failure of motor’s components can cause the brake not to activate. If this condition occurs, turn the saw “ON” and “OFF” four to five times without contacting the workpiece. If the tool operates but the brake does not consistently stop the blade in about five (5) seconds, DO NOT use saw and have it serviced immediately.
The brake action of this saw is not intended as a safety feature.
Remember to let the saw blade come to a complete stop before raising the blade from the workpiece. As always the guard system is your best protection against unintentional contact with a spinning saw blade. NEVER wedge open or defeat the closing action of the lower guard.
7.
Getting To Know Your Miter Saw
20 |
26 |
2 |
25 |
4 |
1 1 3
5 41
7
8 |
9 |
18 |
13 16
15 |
14 |
11 |
10 |
11 |
21 |
12 |
To avoid injury from accidental starting, remove plug from power source
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 brushes 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. 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 different blade widths to minimize workpiece tearout.
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 especially useful when cutting long workpieces.
8.
Getting To Know Your Miter Saw
36 |
38 |
|
27
39
33
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° to 45° left, 0° to 45° right, 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.
40
35
37
34
24
23
31
32
31
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).
36.Handle Rotation Release Lever – Pulling this 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.
38.Handle Clamp – Locks handle in the selected position.
39.Arbor Lock—Allows the user to keep the blade from rotating while tightening or loosening arbor screw during blade replacement or removal.
40.Front Carrying Handle – Used for lifting the tool.
41.Arbor Laser / 3x Battery
9.
Assembly
Tools Needed For Assembly And Alignment
Combination Square |
H “L W |
ch |
Multi Purpose Tool |
|
|
( |
1.5mm |
( |
) |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Com |
|
|
|||||
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Draw Light |
Straight Edge of |
10mm 7mm Co |
|||||||
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Line on Board |
Board 3/4" Thick |
||||||||
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Open End W ch |
|||||||||
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Along this Edge |
This Edge Must be |
||||||||
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|||||||||
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Perfe |
|
Should be no Gap or Overlap when Square is Flipped Over in Dotted Position
Disconnect plug from power source before performing any assembly, adjustment or repair to ! WARNING avoid possible injury.
Unpacking And Checking Contents
Before moving the saw: Lock the ! WARNING miter lock knob in 45° position. Lock
bevel lock handle. Pull the head assembly completely toward you and tighten the slide rail lock knob.
Lock head assembly in the down position.
Never carry the tool by the slide rails, this may cause blade 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 “Table of Loose Parts” to make sure all items are accounted for before discarding any packing material.
2.Table of Loose Parts:
QuickAction Clamp - Used to clamp workpieces. Dust Elbow/Dust Bag - Used to collect saw dust.
Multi Purpose Tool - Should be stored on the right 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
If any parts are missing, do not plug ! WARNING in power cord or turn the switch on
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.
Miter Gauge
Lock Knob
UNLOCK
LOCK
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
Washer
Phillips Screw
10.
Assembly
Installation And Removal Of The Blade
Disconnect plug from power source before performing any assembly,
adjustment or repair to avoid possible injury.
1.The miter saw is equipped with a lock pin used to lock the miter saw in the 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.
2.Rotate the lower guard by hand. Loosen front 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.
Lower Guard
Cover Plate
Front
Cover
Plate
Screw
Rear Cover |
Upper |
Blade |
Outer |
Plate Screw |
Guard |
Bolt |
Washer |
Figure 1. Blade Removal
5.Remove the blade bolt, outer washer and the blade. Inner washer does not need to be removed (Figure 2).
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.
Inner
Washer
Upper |
Arbor |
Guard |
Shaft |
Figure 3. Blade Installation
! WARNING To avoid injury, do not use a blade larger or smaller than 12" diameter
and 1" arbor.
7.Replace the outer washer in it’s proper orientation, and tighten blade bolt finger tight. Press the arbor lock and tighten blade bolt securely using multi purpose tool, but do not overtighten.
8.Rotate cover plate clockwise to original position. Tighten the front cover plate screw.
11.
Assembly
Tighten the cover plate screw.
Loose cover plate screw may interfere with and hang-up lower blade guard. Never use saw without cover plate securely in place. Lower guard will not function properly.
9.Be sure the arbor lock is released so the blade turns freely.
After installing a new blade, make sure the blade does not interfere with the table insert at the 0° and 45°
bevel positions. Lower the blade into the table slot and check for any contact with the base or turn table structure. If blade contacts base or table, seek authorized service.
10.Place multi purpose tool in rubber grommet in right rear of tool.
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 Bag |
Dust Elbow |
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
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.
When sawing chemically pressure treated lumber, paint that may be lead based, or any other materials that may contain
carcinogens, use special precautions. A suitable respirator must be worn by all personnel entering the work area. Work area should be sealed by plastic sheeting and persons not protected should be kept out until work area is thoroughly cleaned.
12.
Adjustments
Disconnect plug from power source before performing any assembly,
adjustment or repair to avoid possible injury.
NOTE: Your miter saw was completely adjusted at the factory. However, during shipment, slight misalignment may have occurred. Check the following settings and adjust if necessary prior to using this miter saw.
Checking 0° Bevel
Adjustment
1.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
Blade
|
|
|
|
|
|
|
|
Combination |
Bevel Lock |
||
Square |
|
Lever |
|
Figure 5. Blade Square to Table
Calibrating Blade at 0 degrees (90° to the table)
1.Lift bevel lock lever to release bevel lock.
2.Loosen bolt heads “A” and “B” with 10 mm openend 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 E
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.
7.Tighten setscrew “D”.
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.
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.
5.Verify that bevel lock tension holds the bevel position secure and also allows bevel lock lever to lock down to the point that a solid stop is felt.
6.If necessary, repeat steps 1 – 5 to adjust the tension.
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.
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.
Blade
Combination |
Table |
Bevel Lock |
Square |
|
Lever |
F
Figure 7. Blade 45° To The Table
Figure 8. Calibrating Blade at 45 degrees
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.
14.
Adjustments
Blade Square to Fence
1.Make sure head assembly is pushed forward near the center of the table and slide rail lock knob is tightened.
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
Combination Square
Figure 9. Blade Square to Fence
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
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).
4.Position the indicator to align with the 0° miter mark. Tighten the screw.
60
5 5
0 5
45
40
|
|
|
|
|
|
|
|
|
0 |
|
|
|
|
|
|
|
2 |
2 |
|
|
|
|
|
|
|
|
1 |
0 |
|
|
|
|
|
|
|
2 |
|
|
|
|
|
|
|
|
|
|
|
|
|
2 |
8 |
12 |
6 12 |
|
4 |
1 |
|
|
5 |
|
|
|
|
||||||
|
|
|
|
|
|
|
|
|
0 |
|
|
|
|
|
|
|
5 |
|
1 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
0 |
1 |
|
|
|
35 |
30 |
5 |
|
2 |
|
|
|
|
|
2 |
|
|
|
|
|
|||
0° Mark
Miter Scale
Indicator
Indicator
Adjustment
Screw
Figure 11. Miter Scale Adjustment
15.
Adjustments
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 purpose 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.
|
Kerf |
|
Screws |
60 |
|
5 |
|
5 |
|
50 |
|
5 |
|
4 |
Kerf |
40 |
Inserts
|
|
|
|
|
|
0 |
|
|
|
|
2 |
12 |
0 |
|
|
4 |
2 |
|
|
|
8 12 |
6 12 |
1 |
|
|
5 |
|
|
|
|
|
5 |
|
10 |
|
|
|
|
|
|
|
|
|
|
0 |
1 |
|
|
35 |
30 |
5 |
2 |
|
|
|
2 |
|
|
|
|
Figure 12. 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.)
1.Loosen and turn both Jam Nuts to just above the threaded end of the Depth Stop Bolt (Figure 13).
Depth Stop
Bolt
Depth Stop
Release Button
Jam Nuts
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).
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.
7.Practice slide cutting (with tool unplugged) to verify 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
Do not start the miter saw without ! CAUTION 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
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 To avoid injury always observe the following:
●Unplug electric cord. Before transporting the saw, rotate head and lock assembly to 60° right miter, lock into detent, slide head assembly to the middle of it’s rail, tighten the slide rail lock knob and lock the head assembly in the lowered position.
Lifting Saw
●To avoid back injury, hold the tool close to your body when lifting. Bend your knees so you can lift with your legs, not your back.
●Lift by using the cast-in carry handles at each side of the bottom of the base.
●Alternate lifting method: When picking tool up from ground, use rear carrying handle and front carrying handle (above guard).
●Never 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 and the wire connections resulting in electric shock or fire.
●Observe the position of the saw. People standing behind it could be injured by thrown debris.
●Place the saw on a firm, level surface where there is plenty of room for handling and properly supporting the workpiece.
●Bolt, nail or clamp the saw to its support.
Be careful not to over-drive nail or over-torque the bolt. This could
crack foot or damage base.
Mounting Applications
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 |
Front Carrying |
Handle |
Handle |
1.Each of the four mounting holes should be bolted securely using 5/16" bolts, lock washers, and hex nuts (not included).
2.Locate and mark where the saw is to be mounted.
3.Drill four (4) 5/16" diameter holes through workbench.
4.Place the miter saw on the workbench aligning holes in base with holes drilled in workbench. Install bolts, lock washers and hex nuts. As an alternative, you can mount the saw using drywall screws in the four nail holes.
Supporting surface where saw is to be mounted should be examined carefully after mounting to ensure that no movement can occur during use. If any tipping or walking is noted, secure the workbench or stand before operating the slide compound miter saw.
Bolt Hole
Nail Hole
Figure 14. Workbench Mounting
17.
Mounting the Saw
Portable Mounting Using Clamps
●If necessary, clamp the miter saw to a workbench or table top.
●Place two (2) or more “C” clamps on the clamping 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
●45° Left
●45° Right
To reposition the main handle:
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.
Adjusting the Four-Position Handle
Clamp Tension
1. Open 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 |
|
|
le |
|
|
|
and |
|
|
te |
H |
|
|
|
|
|
|
ta |
|
|
|
o |
|
|
to |
R |
|
Pul |
ll |
|
|
u |
|
|
|
lt |
P |
|
|
o |
|
|
|
R |
|
|
|
otate |
|
|
|
Handle |
|
|
|
Handle Rotation
Release Lever
|
P |
|
u |
|
l |
|
l |
|
t |
Pull to Rotate Handle |
o |
R |
|
|
o |
|
t |
|
a |
|
t |
|
e |
|
H |
|
a |
|
n |
|
dl |
|
e |
Figure 16. Setting Main Handle Position
18.
Basic Saw Operations
Body and Hand Position
Position your body and hands prop- ! WARNING erly to make cutting easier and
safer. Observe the following instructions (Figure 17).
Correct |
Incorrect Use |
Projected Line Of Cut |
|
Figure 17. 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 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.
DRY RUN—It is important to know where the blade will intersect with the workpiece during cutting operations. Always perform the simulated cutting sequence with the power tool switched OFF to gain an understanding of the projected path of the sawblade. Mentally note where the path of sawblade will fall and set up your work to keep your hands and arms out of the path of the spinning blade. Adjust your clamps and fences so that the smooth lower guard and cutting action is not interfered with during cutting operation.
●Hold workpiece firmly against table and fence to prevent movement.
●Keep hands in position until trigger has been released and blade has stopped completely.
●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.
The lower guard may not automatically open under certain cutting conditions.
For example, when trying to cut work-pieces that are near the maximum cutting height capacity. Under these conditions 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.
Lip
Lower
Guard
Workpiece
Figure 18. Raising Lower Guard
19.
Basic Saw Operations
Workpiece Support
Long workpieces have a tendency to tip over unless clamped down and
properly supported from underneath.
Clamps
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.
There may be extreme compound cuts where clamp cannot be used.
Support workpiece with hand outside No Hands Zone. Do not try to cut short pieces that cannot be clamped and cause your hand to be in the No Hands Zone.
Long workpiece 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 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 |
Hole |
Post |
|
Clamp |
|
Hole |
|
Screw Rod
Figure 19. Quick-Action Clamp
Horizontal Clamp – The optional MS1221 Horizontal 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.
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
Figure 21. Block Support
20.
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 0° bevel position only.
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" pilot holes through auxiliary fence and run screws through rear of metal fence.
5.Make a full depth cut to create the blade slot. Check for interference between the auxiliary fence
and the lower blade guard. Make adjustments as necessary.
! WARNING |
Check for interference from any |
components. |
|
|
Blade Slot |
Auxiliary
Fence
Flat Head
Machine Screws
Figure 22. 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 (Figure 23). When the power switch lever is released, the switch “Lock-OFF” 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 provided with miter saw to prevent unauthorized use.
Power
Switch Lever
Switch “Lock-Off” Release Button
Figure 23. Switch Activation
21.
Basic Saw Operations
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.
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
60
5 5
0 5
5
4
40
|
0 |
|
|
|
2 |
|
Detent |
|
2 1 |
0 |
|
2 |
5 |
||
1 |
|
|
|
2 |
10 |
|
Override Clip |
5 |
|
||
0 |
1 |
|
|
Miter |
Miter |
Detent Lever |
Lock Knob |
Figure 24. Detent Override
Sliding Fences and Base Extensions
So as to provide sufficient (mini- ! WARNING mum 6”) spacing from hand to saw
blade, extend the sliding fences and base extensions when making extreme bevel, miter or compound cuts.
The base extensions can also be used to provide extra support for long workpieces.
Sliding Base:
1.Loosen the base extension clamping levers (Figure 25).
2.Extend sliding base extensions to the desired position.
3.Press the levers down to clamp the extensions into place.
Sliding Fence:
1.Loosen the fence locking knobs (behind fence).
2.Slide fence to proper position.
3.Tighten knobs to lock fence into place.
To Temporarily Remove Sliding Fence:
Some extreme compound angles make it necessary to remove one of the sliding fences.
1.Unscrew fence knob until at least 1/2” of thread shows.
2.Slide fence to its 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.
During transportation, sliding base ! CAUTION 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 |
|
|
|
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 (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. |
|
|
Use clamping position that does not |
|
|
! WARNING interfere with operation. Before |
|
switching on, lower head assembly to make sure |
|
|
clamp clears guard and head assembly. |
|
|
4. Activate the switch. Lower the head assembly and |
|
|
|
make your cut. |
|
5. Wait until blade comes to a complete stop before |
Figure 26. Chop Cut |
|
|
returning head assembly to the raised position |
|
|
and/or removing workpiece. |
|
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 mak-
ing aggressive cuts or cutting thicker materials.
! WARNING NEVER pull the saw toward you during a cut. The blade can suddenly
climb up on top of the workpiece and force itself toward you.
Follow these instructions for making your slide cut:
1. Properly position workpiece. Make sure workpiece is clamped firmly against the table and 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.
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 27).
4.Activate the switch. Lower the assembly all the way down and cut through the edge of the workpiece.
5.Push (but do not force) the head assembly towards the fence to the full rear position to complete the cut.
6.Wait until blade comes to a complete stop before returning head assembly to the raised position and/or removing workpiece.
Figure 27. Slide Cut
23.
Saw Operations
Miter Cut
●A “miter cut” is a cross-cut made with the blade vertical (non-tilted) at a horizontal angle relative to the fence.
●A miter cut is made at 0° bevel and any miter angle in the range from 52° left to 60° right.
●The miter scale shows the angle of the blade relative to the fence angle is cast-in on the table for easy reading.
●Positive detents have been provided for fast and
accurate mitering at 0°, 15°, 22.5°, 31.6° and 45° left and right and 60° right.
●The crown molding detents (left and right) are at 31.6° (See Cutting Crown Molding for more information page 29).
●For precision settings at angles next to the detents, use the detent override to lock out the detent. This prevents the wedge on the detent lever from slipping back into the detent.
●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.
Use clamping position that does not ! WARNING interfere with operation. Before
switching on, lower head assembly to make sure clamp clears guard and head assembly.
4.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 |
|
|
|
|
Miter Lock |
||||
Detents |
||||||||||
|
|
Scale |
Knob |
|||||||
|
|
|
|
|
|
|||||
Figure 28. Miter Cut
Bevel Cut
● A “bevel cut” is a cross-cut made with the blade |
Disengage this stop unless using the 33.9° |
|||||||
perpendicular to the fence but tilted away from the |
angle (See Cutting Crown Molding for details.) |
|||||||
vertical position. |
|
|
|
|
● A bevel cut can be made as either a chop cut or a |
|||
|
|
|
|
|
|
|
||
● A bevel cut is made at 0° miter and any bevel angle |
slide cut depending on the width of the workpiece. |
|||||||
in the range of -47° to 47°. |
|
|
|
● The front-positioned bevel lock lever locks the |
||||
|
|
|
|
|
|
|
||
● The bevel scale is sized and positioned for easy |
head assembly at the desired bevel angle. |
|||||||
reading. |
|
|
|
|
|
1. Lift the bevel lock lever to unlock. Choose the |
||
|
|
|
|
|
|
|
||
● The front-positioned bevel range selector knob |
desired bevel range using the bevel range selector |
|||||||
provides three bevel range choices. |
|
knob. If in the 0° position and moving to the 0°-to- |
||||||
● There are factory set bevel stops at 0° and 45° on |
45° right range or 47°-to-47° range, it may be nec- |
|||||||
essary to move the head assembly slightly to the |
||||||||
both the left and right. (See Adjustment section if |
||||||||
left before the bevel range selector knob can be |
||||||||
adjustments are required.) |
|
|
|
|||||
|
|
|
turned. Applying pressure to the cutting assembly |
|||||
● There |
are |
also |
positive |
crown |
molding |
bevel |
||
may not allow you to move the bevel range selec- |
||||||||
stops |
at |
33.9° |
on both |
the |
left and |
right. |
||
tor Knob. |
||||||||
|
|
|
|
|
|
|
||
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
24. |
|
Bevel Range 1 = 45° Left to 0°
This left side bevel range is the default setting
2. Lift bevel lock lever to the table height 45 - 0
with the left hand (Figure 30). |
Left |
|
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 0-45 assembly and re-lock (Figure 29).
2.Lift bevel lock lever to the table height Right 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:
1.Move left and right-sliding fences to
clear saw assembly and re-lock 47-47 (Figure 29).
2.Lift bevel lock lever to the table height Max
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.
4.Once in the desired bevel position, fully press 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 and Base Extension on page 22).
6.Properly position workpiece. Make sure work piece is clamped firmly against the table and 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.
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
Figure 29.
UNLOCK
LOCK
Bevel Lock
Lever
Figure 30.
|
0 |
|
- |
0 |
45º |
- |
|
45º |
|
Bevel Range Selector Knob
Figure 31.
25.
Saw Operations
Compound Cuts
●A “compound cut” is a cross-cut made with the blade both at a horizontal angle relative to the fence (at a miter angle) and tilted away from the 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.
Use clamping position that does not ! WARNING interfere with operation. Before
switching on, lower head assembly to make sure clamp clears guard and head assembly.
3.Set miter and bevel angles according to the instructions on page 24 and 25 for miter and bevel cuts.
4.Follow the 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
Sliding |
Bevel Angle |
Miter |
Base |
Scale |
Angle |
Figure 32. Compound Cut
26.
Saw Operations
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 33).
2.For minor adjustments, simply rotate the depth stop bolt to the desired location.
Depth Stop
Bolt
Depth Stop
Release Button
Jam Nuts
Figure 33. Cutting Grooves
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 material between the outside grooves (Figure 33a).
Outside Grooves
Workpiece |
Chisel Cut |
Figure 33a. Rough Cut Groove
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.
2.The maximum length that can be cut using the 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.
To increase the length that can be cut using the 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 |
Knob |
|
|
Figure 34. Length Stop
27.
Saw Operations
Cutting Base Molding
●Base molding can be cut vertical against fence or flat on the table. The maximum size that can be vertical on the fence is 4-1/4", flat on table is 10-1/4".
●Follow the table for helpful hints on cutting base molding for corners that have 90° angles.
●Cutting base molding can be done either as a chop 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
Right
Outside corner of wall
|
ht |
|
ig |
Left |
R |
|
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 |
Miter Angle |
Right at 45° |
Left at 45° |
0° |
0° |
|
|
|
|
|
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 molding must be cuts must |
be positioned |
● See also pages 29 & 30 for miter and bevel angle |
|||||||||||||||
properly to fit exactly. |
|
|
|
|
|
|
|
charts for cutting crown moldings that have |
|||||||||
● There are two ways to cut crown molding: flat on |
38° and 45° spring angles (and the material is |
||||||||||||||||
laid flat on the miter saw base). Each chart lists the |
|||||||||||||||||
table or angled to table and fence. |
|
|
|
|
|
||||||||||||
|
|
|
|
|
exact miter and bevel settings required for a wide |
||||||||||||
● Crown |
molding’s |
“spring |
angle” |
|
is |
the |
angle |
||||||||||
|
range of corner angles. |
|
|
||||||||||||||
between the back of the molding and the bottom |
|
|
|||||||||||||||
● Even |
though these |
angles are |
standards, most |
||||||||||||||
flat surface that fits against the wall. |
|
|
|
|
|||||||||||||
|
|
|
|
rooms do not have angles of exactly 90°, there- |
|||||||||||||
● This |
miter |
saw has special |
miter |
detents |
at |
||||||||||||
fore, you will need to fine tune your settings. |
|||||||||||||||||
31.6° |
and |
bevel |
detents |
at |
33.9°. |
These |
|||||||||||
The optional Bosch DWM40L MiterFinder |
|||||||||||||||||
detents allow you to easily position most crown |
|||||||||||||||||
Digital |
Anglefinder/Protractor measures |
spring |
|||||||||||||||
moldings flat on the table and make precise cuts |
|||||||||||||||||
angles and corner angles, then automatically deter- |
|||||||||||||||||
for 90° corners. (These detents are only for use |
|||||||||||||||||
mines |
the exact |
miter and |
bevel |
settings |
|||||||||||||
with |
crown |
moldings that |
have |
a |
38° |
“spring |
|||||||||||
necessary to make each crown molding cut fit |
|||||||||||||||||
angle”.) |
NOTE: |
These |
detents |
|
cannot |
be |
|||||||||||
|
|
|
|
|
|
||||||||||||
used with 45° crown molding. |
perfectly. |
|
|
|
28. |
Saw Operations
Crown Molding Laying Flat on Table
●Notes: Position workpiece with its back flat on the saw table.
●Always place top edge of molding against fence (Decorative edge is at the bottom of crown molding.)
●"Spring angle" refers to angle between wall and crown molding.
●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 Use clamping position that does not interfere with operation. Before
switching on, lower head assembly to make sure clamp clears guard and head assembly.
3.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.
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) |
(31.6) Left |
(33.9) Right |
Use the right end of the cut |
|
|
Outside Corner |
|
|
Left end (C) |
(31.6) Left |
(33.9) Right |
Use the left end of the cut |
|
|
Right end (D) |
(31.6) Right |
(33.9) Left |
Use the right end of the cut |
|
|
Molding Spring Angle is 45 degrees
|
Miter |
Bevel |
|
(Table) |
(Tilt) |
|
Setting |
Setting |
Inside Corner |
|
|
Left end (A) |
(35.3) Right |
(30.0) Left |
Use the left end of the cut |
|
|
Right end (B) |
(35.3) Left |
(30.0) Right |
Use the right end of the cut |
|
|
Outside Corner |
|
|
Left end (C) |
(35.3) Left |
(30.0) Right |
Use the left end of the cut |
|
|
Right end (D) |
(35.3) Right |
(30.0) Left |
Use the right end of the cut |
|
|
29.
Saw Operations
Crown Molding Angled to Table and Fence
The preferred method for cutting crown molding with 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.
NOTE: ALWAYS TAKE A TEST CUT USING 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 measurement 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.
Loading...