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.