Bosch 3915 Operating instructions

IMPORTANT:
Read Before Using
IMPORTANT :
Lire avant usage
IMPORTANTE:
Leer antes de usar
Operating/Safety Instructions
Consignes de fonctionnement/sécurité
Instrucciones de funcionamiento y seguridad
3915
Consumer Information
Renseignement des consommateurs
Información para el consumidor
Toll Free Number:
Appel gratuit :
Número de teléfono gratuito:
1-877-BOSCH99 (1-877-267-2499) http://www.boschtools.com.
For English
See page 2
Parlez-vous français?
Voir page 36
¿Habla español?
Ver página 70
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.
General Safety Rules
For Bench Top Tools
●
Do not expose power tools to rain or wet
conditions. Water entering a power tool will
increase the risk of electric shock.
Work Area
●
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.
●
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.
●
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.
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.
“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 personal 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
●
●
●
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.
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.
●
Service
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.
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: S-B Power Tool Company does not
offer 10” 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 personal 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 compound 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.
WARNING
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.
WARNING
WARNING
FOR SLIDE ACTION CUTTING,
ALWAYS FOLLOW THESE
INSTRUCTIONS:
EXTEND SLIDING
BASE WHEN
MAKING BEVEL
CUTS OR TABLE
IS TURNED TO
LEFT SIDE.
3
5
50
*
40
35
30
25
20
15
10
5
3915
10" (254mm) SLIDE COMPOUND MITER SAW
R
120 VOLTS AC ONLY TO 60 Hz
13 AMPS 4700 RPM
511
DOUBLE INSULATED
LR61595 LISTED 407J
R
SN.
0
45
1. PULL saw carriage away from
the fence, until blade clears
the workpiece or to its maximum extension if blade can
not clear the workpiece.
2. Turn saw “ON” and lower the
saw to the table.
3. PUSH saw thru the workpiece.
Never “pull-cut” since blade
may climb the workpiece
causing KICKBACK.
KEEP HANDS AT A SAFE DISTANCE FROM THE SAW BLADE.
NEVER CROSS YOUR HANDS WITH THE PATH OF SAW BLADE. DO NOT REACH
BEHIND, BENEATH OR IN FRONT OF THE BLADE.
CLAMP WORKPIECE AGAINST BASE AND FENCE. NEVER PERFOAM ANY
OPERATION FREEHAND.
ALL ELECTRIC BRAKE SAWS MAY, ON OCCASIONS, FAIL TO STOP THE BLADE.
AFTER TURNING SAW “OFF”, ALWAYS MAINTAIN SAW HEAD IN DOWN POSITION
AND WAIT FOR BLADE TO STOP BEFORE REMOVING CUTOFF PIECES OR
CLEANING THE TABLE.
R
BO
2
WARNING
BOSCH
H
SC
1
50
DESIGNATED DANGER ZONE.
AVOID POSITIONING HANDS,
FINGERS OR ARMS IN THE
AREA DESIGNATED BY THIS
SYMBOL.
0 601 475 035
READ AND UNDERSTAND
WARNING THE OWNER'S MANUAL
BEFORE USING THIS TOOL.
ALWAYS WEAR SAFETY GOGGLES.
TO AVOID ELECTRICAL SHOCK DO NOT EXPOSE
SAW TO RAIN OR USE IN DAMP LOCATIONS.
USE SAW BLADE RATED 6000 RPM OR GREATER.
DISCONNECT SAW FROM POWER SOURCE
BEFORE SERVICING OR CHANGING BLADE.
WHEN SERVICING USE ONLY IDENTICAL
REPLACEMENT PARTS.
S–B Power Tool Co. Chicago, IL Made in Taiwan
WARNING
KEEP GUARDS IN PLACE.
RETURN GUARD TO OPERATING
POSITION AFTER CHANGING THE BLADE.
IF GUARD FAILS TO WORK SMOOTHLY, STOP
SAWING AND SERVICE IT BEFORE PROCEEDING.
*
“SAVE THESE INSTRUCTIONS”
5.
10-41
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.
●
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.
●
Replace damaged cords immediately. Use of
damaged cords can shock, burn or electrocute.
●
If an extension cord is necessary, a cord with
adequate size conductors should be used to prevent excessive voltage drop, loss of power or
overheating. The table shows the correct size to
use, depending on cord length and nameplate
amperage rating of tool. If in doubt, use the next
heavier gauge. Always use U.L. and CSA listed
extension cords.
RECOMMENDED SIZES OF EXTENSION CORDS
Tools
Ampere
Rating
3-6
6-8
8-10
10-12
12-16
25
18
18
18
16
14
120 Volt A.C. Tools
Cord Length in Feet
Cord Size in A.W.G.
50
100
150
16
16
14
16
14
12
16
14
12
16
14
12
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
Blade Square To Table (90°) . . . . . . . . . . . . . . 13
Blade 45° To The Table . . . . . . . . . . . . . . . . . . 14
Blade Square To Fence . . . . . . . . . . . . . . . . . 15
Miter Scale Indicator Adjustment . . . . . . . . . . 15
Kerf Insert . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Depth Stop Adjustment. . . . . . . . . . . . . . . . . . 16
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . 17-18
Mounting Applications . . . . . . . . . . . . . . . . . . 17
Basic Saw Operations. . . . . . . . . . . . . . . . . 19-22
Body and Hand Position . . . . . . . . . . . . . . . . . 19
Workpiece Support. . . . . . . . . . . . . . . . . . . . . 20
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Compound Cuts . . . . . . . . . . . . . . . . . . . . . . . 25
Cutting Grooves (Dado Cut) . . . . . . . . . . . . . . 26
Cutting Base Molding . . . . . . . . . . . . . . . . . . . 27
Cutting Crown Molding . . . . . . . . . . . . . . . . . . 27
Special Cuts. . . . . . . . . . . . . . . . . . . . . . . . . . 30
Maintenance and Lubrication . . . . . . . . . . . . . 31
Troubleshooting . . . . . . . . . . . . . . . . . . . . . 32-33
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
6.
Electrical Requirements
1.
2.
3.
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.
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.
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.
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.
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.
WARNING
Electric Brake
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.
WARNING
To avoid injury from acciden-
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.
Wiring Diagram
WARNING
This wiring diagram can be used only with switch (Part No. 2610911881) supplied with
your miter saw. Other switches may look the same, but internal switch components can be different, thus creating electrical shock hazard if wired according to this diagram.
Black From
Power Cord
Grey From
Brake Lead
Black
From Field
7.
10-45
Getting To Know Your Miter Saw
3
1
2
27
4
5
26
25
H
C
S
O
23
B
24
29
6
20
7
19
21
22
8
9
18
35
10
30
25
50
45
40
35
30
25
20
15
10
5
0
5
10
15
20
12
16
11
7
17
15
10-00a
14
13
16
tal starting, remove plug from power source outlet
before making any adjustments.
tightening or loosening arbor screw during blade
replacement or removal (Figure 34, page 28).
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.
1. Switch “Lock-OFF” Button
This button must be pressed to activate the power
switch.
2. Power Switch
The power switch used with the “Lock-OFF” button
energizes the unit.
3. Switch Handle
This handle contains the switch. The blade is lowered into the workpiece by pushing/pulling down on
the handle.
6. Blade
Use only 10" blades with 5/8" arbor hole.
7. Fence
Supports the workpiece. The fence has a cast in
scale to make repetitive cuts easy. The fence also
has holes which are used to secure an auxiliary
fence if desired.
4. Arbor Lock
Allows the user to keep the blade from rotating while
8.
Getting To Know Your Miter Saw
8. Kerf Inserts
Kerf inserts can be adjusted to different blade widths
to minimize workpiece tear-out.
28
37
9. Miter Detent Override
Allows detent action to be locked out allowing for
micro adjustments to any miter angle.
10. Miter Lock Knob
The miter lock knob locks the miter saw table at any
desired miter angle.
36
35
29
30
11. Miter Detent Trigger
The trigger releases the table from the detent.
12. Miter Scale/Miter Angle Indicator
This scale is cast in on the base of the saw. Indicator
is fastened to the table.
13. Miter Detents
There are ten (10) miter detents for fast and accurate
miter cuts of common miter angles.
14. Table
Sits in base, provides workpiece support, rotates for
desired miter cuts and rotates the head assembly. The
front extended part of the table is called the miter arm.
15. Base
Provides working surface to support workpiece.
16 Tool Mounting Pads
The four corners of the saw provide areas to clamp,
bolt or nail the saw to a flat work surface.
17. Accessory Extension and Stock Stop
Machined holes that accept the extension wing/stop
accessory.
30
34
16
31
33
32
10-21b
16
28. Blade Wrench
Used for tightening/loosening blade and adjusting
bevel stops. Blade wrench is stored in the switch handle.
29. Power Cord
Supplies power to motor. Has molded cord retainer for
storage.
30. Quick Action Clamp Positions
There are four (4) positions behind the fence for the
quick action clamp.
31. Hex Wrench
Used to adjust sliding base/fence, fence and blade
bolt. Hex wrench is stored in the base.
32 Bevel Detent Pin (Crown Molding Setting)
Allows you to easily move the head assembly to the
bevel angle of 33.9°.
33. Bevel Lock Handle
The bevel lock handle locks the head assembly at a
desired bevel angle. Handle ratchets for use in tight
spaces.
34. Bevel Scale
This scale is cast in on the saw. Allows you to read
the bevel angles easily (Figure 7, page 13).
35. Head Assembly Lock Pin
The compound miter saw is equipped with a lock pin
used to lock the head assembly in the lower position.
36. Depth Stop
Allows you to adjust the depth of the blade for cutting
grooves in the workpiece (Figure 14, page 16).
37. Brush Caps
These caps keep the motor brushes in position and
provide easy access for inspecting and replacing
brushes.
18. Sliding Base/Fence
This provides extra support and clamping area for
compound miter cuts.
19. Chip Deflector
This protects against large chips from entering the
upper guard.
20. Dust Chute Elbow
The dust chute elbow rotates 360° and can accommodate the dust bag or a 1-1/4" vacuum hose hookup.
21. 0° Bevel Stop
Adjustable stop for a quick and accurate 0° bevel
index.
22. 45° Bevel Stop
Adjustable stop for a quick and accurate 45° bevel
index.
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
Provides fast clamping of workpiece.
26. Lower Guard Actuation Link
Allows for smooth movement of the lower guard.
27. Upper Blade Guard
Covers upper portion of the blade.
9.
Assembly
Tools Needed For Assembly And Alignment
Phillips Screwdriver
Blade Wrench
(supplied)
Hex “L” Wrench
(supplied) 6mm
Combination Square Must be True
Combination Square
Draw Light
Line on Board
Along this Edge
Straight Edge of
Board 3/4" Thick
This Edge Must be
Perfectly Straight
Should be no Gap or Overlap
when Square is Flipped Over in
Dotted Position
10-37
WARNING
Disconnect plug from power source before performing any assembly, adjustment or
repair to avoid possible injury.
Unpacking And Checking Contents
2.
CAUTION
Before moving the saw:
Lock the 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.
Table of Loose Parts:
Quick Action Clamp - Used to clamp workpieces.
Dust Elbow/Dust Bag - Used to collect saw dust.
Never carry the tool by the slide rails, this may
cause blade misalignment.
Hex Wrench - Should be stored on the left rear
base.
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.
Blade Wrench - Should be stored in the handle.
WARNING
If any parts are missing, do
not plug in power cord or turn the switch on until the
missing parts are obtained and are installed correctly.
Model 3915 Slide Compound Miter Saw is shipped
complete in one box.
1. Separate all parts from packing materials and
check each one with the “Table of Loose Parts” to
make sure all items are accounted for before discarding any packing material.
10.
Assembly
Installation And Removal Of The Blade
WARNING
Outer Washer
Disconnect plug from power
source before performing any assembly, adjustment
or repair to avoid possible injury.
1.
Arbor Washer
The slide compound 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 screw (see
Depth Stop Adjustment, page 16) slightly so the
handle can be pushed down and the lock pin can
be pulled out.
2.
Blade Bolt
(Left Hand Thread)
Sawblade
Loosen the rear cover plate screw using a
Phillips screwdriver (Figure 1).
3.
Rotate the lower guard by hand. Remove the
front cover plate screw using a Phillips screwdriver (Figure 1).
4.
Rotate the cover plate counterclockwise so the
blade bolt is exposed (Figure 1).
5.
Press and hold the arbor lock. Use the blade
wrench to remove the blade bolt by turning
wrench clockwise. NOTE: The blade bolt has
a left hand thread.
Rear Cover
Plate Screw
10-33
Figure 2. Blade Hardware
7.
To install the 10" blade, fit blade between the
chip deflectors and onto arbor shaft (Figure 3).
NOTE: Make sure the rotation arrow on the
blade matches the clockwise rotation arrow on
the lower guard.
H
Cover
Plate
Lower Guard
Inner Washer
SC
BO
H
SC
BO
Arbor
Shaft
Inner
Washer
Chip Deflector
Front Cover
Plate Screw
Blade Bolt
Outer
Chip Deflector
Washer
Figure 3. Blade Installation
WARNING
To avoid injury, do not use a
blade larger or smaller than 10" diameter and 5/8"
arbor.
10-20a
Figure 1. Blade Removal
6.
10-19a
8.
Replace the outer washer in the proper orientation, insert the arbor washer, and tighten blade
bolt finger tight. Press the arbor lock and tighten blade bolt securely using blade wrench, but
do not overtighten.
9.
Rotate cover plate clockwise to original position.
Install the cover plate screw and tighten.
Remove the blade bolt, arbor washer, outer
washer and the blade. Inner washer does not
need to be removed (Figure 2).
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.
WARNING
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. Be sure the arbor lock is released so the blade
turns freely.
11. Replace blade wrench in storage on saw handle.
WARNING
Assembling Dust Elbow And Dust Bag
1.
With the miter arm locked in the down position,
push the dust elbow onto the dust nozzle. Rotate
elbow to the desired position. (Figure 4).
3.
Position dust elbow/bag so that it does not
interfere with the tool during the cutting operation
for all miter/bevel settings. Make sure dust bag
does not interfere with the slide rails during slide
cutting.
4.
The dust bag requires emptying when full of
sawdust. Empty it frequently and after completion of sawing. Carefully remove dust bag from
dust elbow. Empty dust bag in proper trash bin
by unzipping the bag. Be extremely careful of
dust disposed, materials in fine particle form may
be explosive. Do not throw sawdust on an open
fire. Spontaneous combustion, may in time,
result from mixture of oil or water with dust
particles.
Dust Elbow
Dust Bag
WARNING
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.
10-01a
Figure 4. Dust Bag and Elbow
2.
The dust bag attaches to the dust chute elbow
and is used to collect sawdust. The dust elbow
can also be attached to a standard 1-1/4" vacuum tube for dust collection.
12.
Adjustments
the blade makes contact with the full length of
the square. Tighten jam nut (Figure 6).
WARNING
Disconnect plug from power
source before performing any assembly, adjustment
or repair to avoid possible injury.
0° Stop
NOTE: Your slide compound 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 compound miter saw.
Blade Square To Table (90°)
1.
Rotate table to 0° position and lock in place.
2.
Make sure head assembly is pushed back fully
against stop and slide rail lock knob is tightened.
3.
Lower the blade and engage the lock pin. Use
a combination square to check blade squareness to 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.
0° Stop
Screw
Jam Nut
10-22a
Figure 6. Bevel 0° Stop Screw and Jam Nut
BOSCH
f. Adjust bevel indicator. Loosen screw and
align indicator to the 0° mark. Tighten screw
(Figure 7).
50
Table
Blade
5
50
0
45
40
35
30
25
20
15
10
5
Adjust To 0°
Combination Square
10-04b
0
Figure 5. Blade Square to Table
15
90° Blade Alignment
30
33.9
a. Loosen bevel lock handle.
Screw
b. Lower 0° stop screw and jam nut using blade
wrench supplied in the handle.
Bevel
Scale
45
Bevel
Indicator
c. Grasp switch handle, move the head
assembly left or right until blade makes contact with the full length of the square.
d. Tighten bevel lock handle.
1.
e. Adjust 0° bevel stop screw so that the hex
screw head hits the 0° stop at the same time
2.
13.
Figure 7. Bevel Indicator
Rotate table to 0° position and lock in place.
Make sure head assembly is pushed back fully
against stop and slide rail lock knob is tightened.
Adjustments
Blade 45° To The Table
3.
Lower head assembly. Lock in place.
4.
Loosen bevel lock handle and tilt the head
assembly to 45° bevel. Check the 45° bevel stop.
The bevel indicator should be on the 45° mark,
the 45° bevel stop should be in full contact with
the 45° bevel stop screw, and the blade should
contact the full length of the combination square
(Figure 8).
Blade
SC
H
If the blade is not 45° with the table, adjust 45°
bevel stop.
50
5.
BO
0
50
45
40
35
30
25
20
15
10
5
45° Blade Alignment
Table
a. Lower the 45° bevel stop screw jam nut
using blade wrench supplied in the handle.
Combination
Square
b. Grasp switch handle, move the head
assembly left or right until blade makes contact with the full length of the square.
Figure 8. Blade 45° To The Table
10-04c
c. Tighten the bevel lock handle.
45° Stop
d. Adjust 45° bevel stop screw so that the hex
screw head hits the 45° stop at the same
time the blade makes contact with the full
length of the square. Tighten 45° jam nut
(Figure 9).
45° Stop
Screw
e. Check that bevel indicator is pointing to the
45° mark on the bevel scale (see Figure 7). If
bevel indicator is not aligned with the 45°
mark, first recheck the blade squareness to
the table and 0° bevel indicator alignment.
Then, repeat the 45° blade alignment and
make appropriate adjustments.
0
5
30
45
Jam Nut
Figure 9. Bevel 45° Stop Screw and Jam Nut
14.
Adjustments
Blade Square to Fence
1.
2.
3.
Fence Alignment
Make sure head assembly is pulled forward near
the center of the table and slide rail lock knob is
tightened.
a. The head assembly should remain in lowered
position.
Lower the head assembly, pull the lock pin out
and rotate it 90°, rotate to lock in the
lower 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 10).
b. Use hex wrench (supplied) and loosen three
(3) hex cap screws behind fence (Figure 11).
c. Adjust fence until blade and the fence has full
contact with the square.
d. Tighten hex cap screws.
Fence
Hex Cap
Screw
Fence
If blade does not contact the square, follow the
fence alignment procedure.
BOSCH
Fence
50
Hex Cap
Screws
10-07b
Blade
Figure 11. Fence Adjustment
5
50
0
45
40
35
30
25
20
15
10
Hex "L" Wrench
5
Combination Square
10-04d
Miter Scale
Indicator Adjustment
2
2
0
2/1
CM
8/12
4.
6/1
.6
Loosen the Phillips screw that holds the indicator in place (Figure 12).
CM
3.
31
Raise the head assembly to the full-up position.
25
2.
8/1
2
Rotate table to 0° position and lock in place.
20
1.
30
35
22.5
4/12
Indicator
Adjustment
Screw
40
45
Figure 10. Blade Square to Fence
31.6
Position the indicator to align with the 0° miter
mark. Tighten the screw.
45
35
4/12
6/12
22.5
30
25
5
20 1
10
5
0° Mark
Miter Scale
Indicator
Figure 12. Miter Scale Adjustment
15.
10-14a
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 Phillips
screwdriver (Figure 13).
3.
Adjust the kerf inserts as close to the blade
(teeth) as possible without touching the blade.
Kerf Screws
/12
CM /12
8
4/12
2/12
5
Tighten the kerf screws.
10
12
31
5
0 3
25 3
.6
22.5
4.
2
10/1
6/12
15 25
40
45
Kerf Screws
NOTE: At extreme bevel angles the saw blade may
slightly cut into kerf insert.
Kerf Inserts
10-13a
Figure 13. Kerf Insert
Depth Stop Adjustment
—
—
The depth stop adjustment is a feature used
when cutting grooves (or dados) in the workpiece. (See page 26 for cutting grooves.)
Depth Stop
Bolt
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.
Knurled Nut
Depth Stop Base
Jam Nuts
Depth Stop
Follow these instructions for adjusting the depth
stop.
1.
Loosen the two (2) jam nuts on the end of the
depth stop bolt (Figure 14).
2.
Loosen the knurled nut at the top of the arm
(Figure 14).
3.
The saw blade is lowered by turning the depth
stop bolt counterclockwise and raised by turning
the bolt clockwise.
4.
10-12a
Figure 14. Depth Stop Adjustment
Lower the blade into the slot of the turn
table. Check blade clearance and maximum cutting distance (distance from fence where blade
enters) to front of work table slot. Adjust if necessary.
CAUTION
Do not start the slide compound 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.
16.
5.
Tighten the knurled nut at the top of the
arm.
6.
Tighten the two (2) jam nuts against the depth
stop base.
Installation
WARNING To avoid injury always observe
●
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.
the following:
●
●
●
Unplug electric cord. Before transporting the
saw, rotate head assembly to 45° right miter,
lock into detent, pull the head assembly completely forward toward you, tighten the slide rail
lock knob and lock the head assembly in the
lowered position.
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.
CAUTION
Be careful not to over
drive nail or over torque the bolt. This could
crack foot or damage base.
Never carry the tool by the slide rails, this
may cause blade misalignment.
Mounting Applications
Workbench
1.
Mount the saw using either the four bolt holes (7/16")
or the four nail holes to the workbench (Figure 15).
Check for clearance to the left and right of the saw.
Each of the four mounting holes should be bolted securely using 7/16" bolts, lock washers, and
hex nuts (not included).
2.
Locate and mark where the saw is to be mounted.
3.
Drill four (4) 7/16" diameter holes through workbench.
4.
Place the slide compound miter saw on the
workbench aligning holes in base with holes
drilled in workbench. Install bolts, lock washers and hex nuts.
H
C
OS
B
Nail Hole
Bolt Hole
Bolt Hole
Nail Hole
30
35
40
45
50
Supporting surface where saw is to be mounted
should be examined carefully after mounting to insure
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.
50
45
40
35
30
25
20
15
10
5
0
Bolt Holes
Nail Holes
10-29a
Figure 15. Workbench Mounting
17.
Installation
Portable Mounting Using Clamps
H
If necessary, clamp the slide compound miter
saw to a workbench or table top.
—
Place two (2) or more “C” clamps on the clamping areas and secure (Figure 16).
SC
BO
Clamping Area
30
35
40
45
50
—
50
45
40
35
30
25
20
15
10
5
0
Clamping Areas
10-29b
Figure 16. Portable Mounting Using Clamps
Portable Mounting Using 2x4’s
H
SC
45
The cast-in carry handle openings have ribs on
the inside that are the same size as a 2x4.
Center the miter saw openings over the 2x4’s
which have been clamped or nailed on a work
bench for stability (Figure 17).
40
—
35
In order to avoid any twisting of the saw, the saw
can be placed over (2) 2x4’s mounted on a workbench.
30
—
50
BO
50
45
40
35
30
25
20
15
10
5
0
NOTE: The board does not slide completely through
the opening. The saw must be placed over two (2)
boards, one on each side.
2x4 Nailed to Workbench
10-29c
Figure 17. Portable Mounting Using 2x4’s
18.
Basic Saw Operations
Body and Hand Position
WARNING
WARNING
Position your body and hands
properly to make cutting easier and safer. Observe the
following instructions (Figure 18).
●
Never place hands near cutting area. Keep
hands outside the “No Hands” zone.
●
The “No Hands Zone” is defined as the area
between marked lines on the left and right side of
the Base, including the entire Table and portions
of the Fence within these marked lines. This
zone is labeled by “No Hands” symbols placed
just inside the marked lines on the Base.
●
The lower guard may not automatically open under certain cutting conditions. If this
occurs:
Hold workpiece firmly to the fence to prevent
movement.
●
Keep hands in position until trigger has been
released and blade has stopped completely.
●
Never place hands on slide rails.
Correct
●
Typically this may occur when trying to cut workpieces that are near the maximum cutting height
capacity. Under these conditions, the workpiece
can stop the lower guard movement before the
downward motion of the arm could pre-open the
lower guard. If this occurs:
●
Workpiece must be securely clamped. This
frees a hand to raise the guard by the lip just
enough to clear the workpiece (Figure 19).
●
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.
Incorrect Use
H
Lip
H
SC
SC
BO
BO
Lower Guard
H
50
45
50
45
40
35
30
30
35
40
45
50
SC
50
45
40
35
30
40
35
25
20
15
10
5
BO
30
0
25
20
15
10
0
5
H
H
SC
SC
BO
BO
50
45
30
30
35
35
40
40
45
45
50
50
Open
50
45
40
35
30
40
35
25
20
15
10
5
0
30
25
20
15
10
5
0
10-29i
Workpiece
Figure 18. Hand Positions
●
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.
●
Before making any cut, with the power off, lower
the blade to preview the blade path.
Figure 19. Raising Lower Guard
19.
10-23a
Basic Saw Operations
Workpiece Support
WARNING
Long workpieces have a tendency to tip over unless clamped down and properly
supported from underneath.
Long Workpiece Support
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).
Clamps
Quick Action Clamp - This clamp easily secures a
workpiece in any of four (4) clamp holes behind the
fence (Figure 20).
—
50
45
—
—
Two 2x’s
and One 1x’s
40
—
BO
35
—
H
SC
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.
30
—
25
50
45
40
35
30
25
20
15
10
5
0
WARNING
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.
Quick
Action
Clamp
10-29d
Figure 21. Block Support
Extension Wing and Stock Stop - This attachment
(accessory #BA162) allows extra support for the
longer workpieces. Refer to the accessory instruction
sheet for details (Figure 22). See page 34 for a complete accessory list.
CH
S
BO
Clamp
Holes
Clamp
Post
Clamp
Holes
H
SC
BO
50
30
35
4
0
45
50
Extension Wing
and Stock Stop
45
40
30
25
20
15
10
5
0
30
35
40
45
50
35
50
45
40
35
30
25
20
15
10
5
0
Screw Rod
10-29j
Figure 20. Quick Action Clamp
Extension Wing
and Stock Stop
Conventional Clamps and other hold down devices
can be used to hold the workpiece firmly against the
table and the fence.
10-29e
Figure 22. Extension Wing and Stock Stop
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.
H
SC
BO
Flat Head
Machine
Screws
1. Place a piece of wood against the miter saw
fence (Figure 23). (Wood can have a maximum height of 3-1/4". Check that head
assembly does not interfere with auxiliary
fence.)
2. Mark the locations of the support holes on
the wood from the back side of the fence.
50
30
35
40
45
50
3. Drill and countersink the holes on the front of
the support board.
45
40
35
4. Attach the auxiliary fence using three (3) 1/4"
flat head machine screws. 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
30
25
20
15
10
5
Auxiliary
Fence
0
Blade Slot
10-29f
Figure 23. Auxiliary Fence
Check for interference from
any components.
Switch Activation
The safety switch is designed to prevent accidental
starts. To operate safety switch, press the switch
“Lock-OFF” button with your thumb (or index finger for
left hand) to disengage the lock, then pull the power
switch trigger and release the switch “Lock-OFF” button (Figure 24). When the power switch trigger is
released, the switch “Lock-OFF” button will engage
the safety switch automatically, and the trigger will no
longer operate.
Switch
“Lock-OFF”
Button
H
SC
BO
Power
Switch
NOTE: Switch can accommodate a padlock with a
long shackle of up to 1/4" in diameter (not provided
with slide compound miter saw) to prevent unauthorized use.
10-29k
Figure 24. Switch Activation
21.
Basic Saw Operations
Detent Override
To Engage:
Clip Edge
1.
Lift the miter detent trigger.
2.
Push the detent override clip forward and latch in
place over edge. Release miter detent trigger
(Figure 25).
3.
Move miter arm to any position on the miter
scale.
4.
Lock the miter lock knob to retain miter position.
Detent Override Clip
0
5
To Disengage:
5.
Loosen miter lock knob and lift the miter detent
trigger to release the detent override clip. The
clip should automatically disengage and the
table should lock into any desired miter detent.
Table
Miter Detent
Trigger
Miter Lock
Knob
10-24a
Figure 25. Detent Override
Sliding Base/Fence Extension
WARNING
Extend and use sliding
base/fence when making severe bevel, severe miter
or compound cuts to provide sufficient (minimum 6")
spacing from hand to saw blade.
1.
Remove hex wrench from storage position on
left rear leg.
2.
Loosen two (2) socket cap screws in sliding
base channel (Figure 26).
Sliding
Base/Fence
12
/12
10
/12
50
8/1
2
45
6/12
40
3.
4.
4/12
35 33.5
30
Extend sliding base/fence to the desired position.
Tighten screws. Store hex wrench.
Socket Cap
Screws
CAUTION
During transportation, sliding
base should always be secured in the full in position.
Figure 26. Sliding Base/Fence
22.
25 22.5
2/12
20
15
10-15a
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.
5.
Slide Completely
Against Rest
Follow these instructions for making your chop
cut:
1.
Slide the head assembly to the rear as far as it
will go (Figure 27).
2.
Tighten the slide rail lock knob (Figure 27).
3.
Properly position workpiece. Make sure workpiece is clamped firmly against the table and the
fence.
Wait until blade comes to a complete stop
before returning head assembly to the raised
position and/or removing workpiece.
Slide Lock
Knob
Tightened
H
SC
BO
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.
10-05a
Activate the switch. Lower the head assembly
and make your cut.
Figure 27. 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.
See page 34 for accessory blade listing.
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.
4.
Activate the switch. Lower the assembly all the
way down and cut through the edge of the workpiece.
5.
Push (but do not force) the head assembly
towards the fence to the full rear position to
complete the cut.
6.
Wait until blade comes to a complete stop before
returning head assembly to the raised position
and/or removing workpiece.
First:
Pull
Forward
Follow these instructions for making your slide
cut:
1.
H
SC
BO
Second:
Turn
Saw On
Properly position workpiece. Make sure workpiece is clamped firmly against the table and
the fence.
Lower
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
28).
50
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.
5
0
50
45
40
35
30
25
20
15
10
5
Third:
Push
Blade Into
Workpiece
Workpiece
Quick Action
Clamp
Figure 28. Slide Cut
23.
10-23b
Saw Operations
Miter Cut
—
A miter cut is made at 0° bevel and any miter
angle in the range from 52° left to 62° right.
—
The miter scale is cast-in on the table for easy
reading.
—
Positive detents have been provided for fast
and accurate mitering at 0°, 15°, 22.5°, and
45° left and right and 60° right.
—
There are crown molding detents (left and right)
at 31.6° (see Cutting Crown Molding for more
information page 27).
—
For precision settings, use the detent override
to lock out the detent.
—
A miter cut can be made as either a chop cut or
a slide cut depending on the width of the workpiece.
—
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.
Quick Action
Clamp
H
SC
BO
The kerf inserts should be as close to the blade
as possible without touching the blade (see Kerf
Inserts for adjustment procedures).
Miter
Lock
Knob
Follow these instructions for making your miter
cut:
045
40
40
2.
Loosen miter lock knob. Lift miter detent trigger
and move the saw to the desired angle, using
either the detents or the miter scale. Tighten
miter lock knob (Figure 29).
550
1.
35
3030
25
2020
15
10 5
10
00 5
10 15
10
20
20 25
30
30
0
35 440
45
50
Workpiece
Miter Scale
Properly position workpiece. Make sure work
piece is clamped firmly against the table and the
fence.
Detents
10-17a
Figure 29. Miter Cut
Bevel Cut
—
A bevel cut is made at 0° miter and any bevel
angle in the range of -2° to 47°.
—
There are factory set bevel stops at 0°
and 45°. (See Adjustment section if adjustments are required.)
—
The cast in bevel scale faces the operator for
easy reading.
—
There is a positive crown molding bevel stop at
33.9°. Disengage this stop unless using.
(See Cutting Crown Molding for details.)
24.
—
A bevel cut can be made as either a chop cut or
a slide cut depending on the width of the workpiece.
—
The bevel lock handle is spring loaded and can
be repositioned by pulling handle out, rotating to
desired position and engaging by releasing for
use in tight spaces.
—
Use sliding base/fence as appropriate.
(See Sliding Base/Fence Extension page 22.)
Saw Operations
Follow these instructions for making your bevel
cut:
Loosen the bevel lock handle. Tilt the head
assembly to desired bevel angle. Tighten the
bevel lock handle (Figure 30).
2.
Properly position workpiece. Make sure work
piece is clamped firmly against the table and the
fence.
Bevel
Angle
Workpiece
0
1.
Quick
Action
Clamp
5
30
45
WARNING
4
35
0
4.
5
3.
04
5
Use clamping position that
does not interfere with operation. Before switching on,
lower head assembly to make sure clamp clears
guard and head assembly.
Follow the procedures for either a chop cut or
slide cut (see page 23).
30
25
20
15
10
5
25 30
10 15 20
0
35
40
45
0° Miter
Wait until blade comes to a complete stop before
returning head assembly to the raised position
and/or removing workpiece.
10-25a
Figure 30. Bevel Cut
Compound Cuts
—
A compound cut is a cut requiring both a miter
setting and a bevel setting.
—
A compound cut can be made as either a chop
cut or a slide cut depending on the width of the
workpiece.
—
4.
Wait until blade comes to a complete stop before
returning head assembly to the raised position
and/or removing workpiece.
Quick
Action
Clamp
Because it may take several tries to obtain the
desired compound angle, perform test cuts on
scrap material before making your cut.
Bevel
Angle Scale
Follow these instructions for making your compound cut:
1.
Extend the sliding base/fence when making compound cuts that are mitered to the left (see
Sliding Base/Fence Extension on page 22).
Select the desired miter and bevel angles (Figure
31). (See Miter Cut and Bevel Cut on page 24.)
2.
Properly position workpiece. Make sure work
piece is clamped firmly against the table and the
fence.
5
5
10
Sliding
Base
Miter Angle
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.
0
15
45 50
35 40
20 25 30
Workpiece
Figure 31. Compound Cut
Follow the procedures for either chop cut or slide
cut (see page 23).
25.
10-26a
Saw Operations
Cutting Grooves (Dado Cut)
—
The depth stop adjustment is a feature used
when cutting grooves (dados) in the workpiece.
—
The depth adjustment is used to limit blade
depth to cut grooves.
—
A groove can be cut as a slide cut.
1.
Set the depth of cut by loosening the knurled nut
on the depth adjustment bolt (Figure 32). Do not
change the position of the two (2) jam nuts on
the end of the bolt.
2.
3.
Tighten the knurled nut.
4.
Cut the two outside grooves.
5.
Use a wood chisel or make multiple passes by
sliding the wood over to one side to remove the
material between the outside grooves (Figure 33).
Grooves
Chisel Cut
Turn the depth stop bolt to the correct setting.
Depth Stop
Bolt
Knurled Nut
Depth Stop Base
Jam Nuts
Depth Stop
Workpiece
10-42
Figure 33. Rough Cut Groove
10-12a
Figure 32. Cutting Grooves
26.
Saw Operations
Cutting Base Molding
—
Base molding can be cut vertical against fence
or flat on the table.
—
Follow the table for helpful hints on cutting base
molding.
—
Cutting base molding can be done either as a
chop cut or a slide cut depending on the width of
the workpiece.
BASE MOLDING CUTTING INSTRUCTIONS
SETTINGS
/
INSTRUCTIONS
Vertical Position
Back of molding is
against the fence
Horizontal Position
Back of molding is flat
on the table
Bevel Angle
0°
45°
Molding position
Inside
corner of wall
Left
Righ
t
Outside
corner of wall
Left
t
Righ
Left Side
Right Side
Left Side
Right Side
Miter Angle
Left at 45°
Right at 45°
0°
0°
Molding
position
Bottom
against table
Bottom
against table
Top against
fence
Bottom
against fence
Finished
side
Keep left
side of cut
Keep right
side of cut
Keep left
side of cut
Keep left
side of cut
Miter Angle
Right at 45°
Left at 45°
0°
0°
Molding
position
Bottom
against table
Bottom
against table
Bottom against
fence
Top against
fence
Finished
side
Keep left
side of cut
Keep right
side of cut
Keep right
side of cut
Keep right
side of cut
Cutting Crown Molding
—
Crown molding must be cut exactly to fit properly.
—
There are two ways to cut crown molding:
flat on table or
angled to table and fence.
—
Your miter saw has special miter detents of
31.6° left and right and a bevel detent of 33.9°
for cutting crown molding flat on the table.
—
52° between the back of the molding and the
top flat surface that fits against the wall.
38° between the back of the molding and the
bottom flat surface that fits against the wall.
NOTE: These detents cannot be used with 45° crown
molding.
These special detents angles have been
designed into your compound miter saw for the
standard crown molding used in the United
States with the following angles:
27.
—
Even though these angles are standards, most
rooms do not have angles of exactly 90°, therefore, you will need to fine tune your settings
using the detent override.
—
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.
Saw Operations
Crown Molding Laying Flat on Table
Arbor Lock
Follow these instructions for cutting crown
molding:
1.
Set the bevel and miter angles using Chart 1
below. Tighten the miter lock knob and the
bevel lock handle (Figure 34).
2.
Position molding on saw table. Use the chart
below for correct position. Clamp workpiece in
place using the quick clamp.
Quick
Action
Clamp
Crown
Molding
33.9° Bevel
WARNING
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.
50
Use clamping position that
does not interfere with operation. Before switching on,
lower head assembly to make sure clamp clears
guard and head assembly.
45
40
35
30
25
20
15
10
5
0
5
10
15
20
25
30
35
31.6° Miter
10-27a
Figure 34. Crown Molding Laying Flat
NOTE: ALWAYS TAKE A TEST CUT USING
SCRAP TO CONFIRM CORRECT ANGLES.
Chart 1: Crown Molding, Miter and Bevel Settings
28.
Saw Operations
Crown Molding Angled to
Table and Fence
—
—
Crown Molding
Angled Against Fence
The advantage to cutting in this position is
that no bevel setting is required. Cutting is
done with 45° miter angle.
550
The maximum crown molding width that can be
cut and angled to table and fence is 4-1/4".
However, there is no practical way to clamp the
molding. The preferred method for cutting crown
molding with this saw is with the molding laying
flat on the table.
045
40
40
Follow these instructions for cutting crown molding angled to table and fence.
1.
2.
4.
Follow the procedures for chop or slide cut (see
page 23).
3030
25
2020
15
10 5
10
00 5
10 15
10
20
20 25
30
30
0
35 440
45
50
10-28a
Figure 35. Crown Molding Angled to
Table and Fence
Set the miter angle using Chart 1. Tighten the
miter lock knob (Figure 35).
Support crown molding against the fence (see
“Body and Hand Position” on page 19.)
35
45° Miter
Position the molding so the bottom (part which
is installed against the wall) is against the fence.
3.
H
SC
BO
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.
29.
Saw Operations
Special Cuts
Cutting bowed material and round material are only
examples of special cuts.
Quick
Action
Clamp
Cutting Bowed Material
H
SC
BO
WARNING
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 cut. Bent or warped workpieces can twist or rock
and may cause binding on the spinning saw blade
while cutting (Figure 36).
Fence
50
30
35
40
45
50
No Gap at
this Point
45
40
35
30
25
20
15
10
0
5
Bowed Material
10-29g
Figure 36. Bowed Material
Cutting Round or Irregularly
Shaped Material
Quick
Action
Clamp
WARNING
For round material such as
dowel rods or tubing, always use a clamp or a fixture
designed to clamp the workpiece firmly against the
fence and table. Rods have a tendency to roll while
being cut, causing the blade to “bite” and pull the work
with your hand into the blade (Figure 37).
H
SC
BO
50
30
35
4
0
45
50
Fence
45
40
35
30
25
20
15
10
5
0
Round Material
10-29h
Figure 37. Round Material
30.
Maintenance and Lubrication
Service
Cleaning
WARNING
Preventive maintenance performed by unauthorized personnel may result in misplacing of internal wires and components which could
cause serious hazard. We recommend that all tool
service be performed by a Bosch Factory Service
Center or Authorized Bosch Service Station.
WARNING
To avoid accidents, always disconnect the tool from the power supply before cleaning or performing any maintenance. The tool may be
cleaned most effectively with compressed air. Always
wear safety goggles when cleaning tools with compressed air.
Carbon Brushes
Ventilation openings and switch levers must be kept
clean and free of foreign matter. Do not attempt to
clean by inserting pointed objects through openings.
The brushes and commutator in your tool have been
engineered for many hours of dependable service. To
maintain peak efficiency of the motor, we recommend
every two to six months the brushes be examined.
Only genuine Bosch replacement brushes specially
designed for your tool should be used.
Check regularly to make sure the lower guard and all
moving parts are working properly.
Remove accumulated sawdust from working parts by
blowing with compressed air or wiping with a damp
cloth.
Motor Brush Replacement
To Inspect or Replace Brushes:
1.
Unplug the saw.
CAUTION
Certain cleaning agents and
solvents damage plastic parts. Some of these are:
gasoline, carbon tetrachloride, chlorinated cleaning
solvents, ammonia and household detergents that
contain ammonia.
CAUTION
The brush cap is spring loaded
by the brush assembly.
2.
Remove the brush cap on the motor using a
wide flat blade screwdriver.
3.
Pull out the brush (Figure 38). Repeat for the
opposite side.
Care of Blades
Blades become dull even from cutting regular lumber.
If you find yourself forcing the saw forward to cut
instead of just guiding it through the cut, chances are
the blade is dull or coated with wood pitch.
NOTE: If installing the existing brush or brushes,
make sure the brush goes in the same way it came
out. Otherwise a break-in period will occur that will
reduce motor performance and increase brush wear.
4.
Inspect brushes for wear. On the wide flat side of
brush is a wear limit line. If the brush contact
face is at or beyond (no line visible) the limit
replace brushes as a set.
5.
Install new brush. The two (2) tabs on the brush
terminal go in the same hole the carbon part fits
into.
6.
Tighten the brush cap but do not overtighten.
When cleaning gum and wood pitch from blade,
unplug the saw and remove the blade. Remember,
blades are designed to cut, so handle carefully. Wipe
the blade with kerosene or similar solvent to remove
the gum and pitch. Unless you are experienced in
sharpening blades, we recommend you do not try.
Tool Lubrication
Your Bosch tool has been properly lubricated and is
ready to use. It is recommended that tools with gears
be regreased with a special gear lubricant at every
brush change.
Periodically lubricate moving parts with a silicone, or
light oil spray. Do not use grease because it tends to
attract and hold sawdust.
Bearings
0
5
30
45
Brush
All bearings in this tools are lubricated with a sufficient
amount of high grade lubricant for the life of the unit
under normal operating conditions. No further lubrication is required.
Brush
Terminal
Figure 38. Motor Brush
31.
Troubleshooting
Troubleshooting Guide - Electrical
PROBLEM
Brake does not stop blade in
about 5 seconds
Motor does not start.
Flash of light from motor endcap
when switch is released.
CAUSE
CORRECTIVE ACTION
1. Brushes not seated or lightly
sticking or worn.
-
Inspect/clean or replace
brushes (see Maintenance
Section).
2. Motor overheated from use
of dull blade/too heavy of a
blade, not recommended
accessory or rapid on/off
cycling.
-
Use sharp blade.
Use a recommended blade.
Let saw cool down.
3. Blade bolt loose.
-
Tighten blade bolt.
4. Other
-
Authorized service
1. Check that unit is plugged in.
-
Plug unit in. Use different
outlet.
2. Power source fuse or
time delay fuse.
-
15-Amp time delay fuse or
circuit breaker.
3. Brushes worn.
-
See Brush Replacement in
the Maintenance and Lubrication section.
4. Other.
-
Authorized service.
1. Normal - brake working properly.
32.
Troubleshooting
Troubleshooting Guide - General
CAUSE
PROBLEM
CORRECTIVE ACTION
Blade hits table.
1. Misalignment
- Authorized service.
Angle of cut not accurate.
1. Misalignment
- See Adjustments section.
Cannot move miter adjustment.
1. Lock knob tightened/detent
engaged.
- Loosen lock knob/move out
of detent.
2. Sawdust under table.
- Vacuum or blow out dust.
Wear eye protection.
3. Blade interferes with fence.
- Authorized service.
1. Part failure.
- Authorized service.
2. Pivot spring or guard spring
not replaced properly after
service.
- Authorized service.
3. Cover plate not tightened
after replacing blade.
- See Blade Installation page
11.
4. Sawdust accumulation.
-
1. Improper operation.
- See Basic Saw Operation
section.
2. Dull blade.
- Replace or sharpen blade.
3. Improper blade.
- Replace with 10” diameter
blade designed for the material being cut.
4. Bent blade.
- Replace blade.
1. Saw blade not round.
- Replace blade.
2. Saw blade damaged.
- Replace blade.
3. Saw blade loose.
- Tighten arbor screw.
4. Other.
- Authorized service.
Head assembly does not move
from 33.9° position.
1. Bevel detent lock pin
engaged.
- Pull lock pin out and rotate
90°.
Blade does not completely cut
workpiece.
1. Depth stop screw adjusted for
groove cutting.
- See Depth Stop Adjustment in
the Adjustment section.
Head assembly does not slide
freely when attempting a slide
cut.
1. Slide rail lock knob tightened.
- Loosen slide rail lock knob.
Head assembly slides forward
and back when making a chop
cut.
1. Slide rail lock knob not tightened.
- Push head assembly completely against stop. Tighten
slide rail lock knob.
Head assembly will not fully rise
or blade guard will not fully close.
Blade binds, jams, burns wood.
Rough cuts.
Tool vibrates or shakes.
33.
Clean head assembly.
Accessories
Various Blades
A range of blades of various materials, tooth configurations and rakes are offered to provide the correct
blade for various applications.
Table Kerf Inserts (BA161)
The table inserts are adjustable so the correct kerf
can be used when making cuts.
Extension Wings and Stock Stop (BA162)
This attachment allows extra support for the longer
workpieces cut in the shop.
10" 40 Tooth Carbide Tipped ATB Thin Kerf 0° Hook
5/8" Arbor (BB1040M)
10" 40 Tooth Carbide Tipped ATB Thin Kerf 13° Hook
5/8" Arbor (BB1040M)
Workpiece Clamp (BA160)
A quick action clamp is provided to clamp workpiece
enabling better control during cutting operations.
10" 60 Tooth Carbide Tipped ATB Thin Kerf 0° Hook
5/8" Arbor (BB1060M)
34.
Notes
35.