Bosch 3912 Assembly instructions

iMPORTANT:
Read Before Using
IMPORTANT'.
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IMPORTANTE:
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Operating/Safety instructions
Consignes de fonctionnernent/s_curit_
Instrucciones de funcionarniento y seguridad
3912
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Safety
r !_v*vl'-_z'l_ll_[e]l "READ ALL INSTRUCTIONS" -- Failure to follow the SAFETY RULES identified by BULLET (I)symbol
listed BELOW and other safety precautions, may result inserious personal injury.
General Safety Rules
For Bench Top Tools
W0rkArea
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 itcomes to a complete stop.
MAKE WORKSHOP CHILDPROOF with padlock,
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 apolarized
plug (one blade is wider than the other). This plug
will fit in apolarized 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 apolarized outlet. Do not change the plug in
any way. Double insulation eliminates the need for the
three wire grounded power cord and grounded power
supply.
Avoid body contact with grounded surfaces such as
pipes, radiators, ranges and refrigerators. There is an
increased risk of electric shock if your body is grounded.
Do not expose power tools to rain or wet conditions.
Water entering a power tool will increase the risk of
electric shock.
Do not abuse the cord. Never use the cord to carry
the tools or pull the plug from an outlet. Keep cord
away from heat, oil, sharp edges or moving parts.
Replace damaged cords immediately. Damaged
cords increase the risk of electric shock.
When operating apower tool outside, use an outdoor
extension cord marked "W-A" or "W'. These cords are
rated for outdoor use and reduce the risk of electric
shock.
Personal Safety
Stay alert, watch what you are doing and use
common sense when operating a power tool. A
moment of inattention or use of drugs, alcohol or
medication while operating power tools can be
dangerous.
Dress properly. Do not wear loose clothing or
jewelry. Contain long hair. Keep your hair, clothing
and gloves away from moving parts. Loose clothes,
jewelry or long hair can be caught in moving parts.
Roll long sleeves above elbows. Rubber gloves and non-
skid footwear are recommended when working
outdoors.
Avoid accidental starting. Be sure switch is "OFF"
before plugging in. Carrying tools with your finger on
the switch or plugging intools 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 injurymay
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.
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
"SAVE THESE INSTRUCTIONS"
2

Safety
r !_v*vl'-_'l_ll_[e]l "READ ALL INSTRUCTIONS" -- Failure to follow the SAFETY RULES identified by BULLET (I)symbol
listed BELOW and other safety precautions, may result inserious personal injury.
ToolUse andCare
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 isdangerous.
Disconnect the plug from the power source before
making any adjustments or changing accessories.
Such preventive safety measures reduce the risk of
starting the tool accidentally.
Keep cutting tools sharp and clean. Properly
maintained tools, with sharp cutting edges, are less likely
to bind and easier to control. When mounting saw
blades be certain that the arrow on the blade matches
the direction of the arrow marked on the tool and that the
teeth are also pointing in the same direction.
, inspect guards before using atool. Keep guards in
place. Check moving parts for binding or any other
condition that may affect the normal operation or
safety features of the tool. if damaged, have tool
serviced before using the tool. Many accidents are
caused by poorly maintained tools.
.Do not alter or misuse tool. Any alteration or
modification is a misuse and may result in serious
personal injury.
•The use of any other accessories not specified in this
manual may create a hazard. Accessories that may be
suitable for one type of tool, may become hazardous
when used on an inappropriate tool.
Service
Tool service must be performed only by qualified
repair personnel. Service or maintenance performed by
unqualified personnel may result in misplacing internal
wires and components which could cause serious
hazard.
When servicing a tool, use only identical replacement
parts. Follow instructions in the Maintenance section
of this manual. Use of unauthorized parts or failure to
follow Maintenance Instructions may create a hazard.
Safety Rules for
Miter Saws
Use clamps to support workpiece whenever
possible, if supporting the workpiece by hand, you
must always keep hand outside of "No Hands" area
as marked with asymbol 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 intothe 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 isvery
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 primarily 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
non=ferrous 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 12" metal cutting blades.)
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 damped 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.
"SAVE THESE INSTRUCTIONS"
3

Safety
!r!_v*vl'-1_'l_ll_[ttl "READ ALL INSTRUCTIONS" -- Failure to follow the SAFETY RULES identified by BULLET (I)symbol
listed BELOW and other safety precautions, may result inserious personal injury.
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 21). 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 workpieces, 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 afixture 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!
I'w,_ wl-],_=l,_r.,-_i[ ___VAV.,_..L_L,,LL_ 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.
• There are additional safety instructions for particular
operations of the saw in the operating section. Read
the rest of the manual for safe operation.
"SAVE THESE INSTRUCTIONS"
4

Safety
IV !_Wl'-_'l_ll_[ctl "READ ALL INSTRUCTIONS"-Failure to follow the SAFETY RULES identified by BULLET (I)symbol
listed BELOW and other safety precautions, may result inserious personal injury.
• Do not aBow famBiarity 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.
m'rm.l-]_ti_r,,._lr,.,=vAv.,_.,,..,,.....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.
DESIGNATED DANGER ZONE.
AVOID POSITIONING HANDS,
FINGERS OR ARMS IN THE
AREA DESIGNATED BY THIS
SYMBOL.
"SAVE THESE INSTRUCTIONS"
5

Safety
r !_v*vl'-_'l_ll_[ttl "READ ALL INSTRUCTIONS" -- Failure to follow the SAFETY RULES identified by BULLET (I)symbol
listed BELOW and other safety precautions, may result inserious personal injury.
DoubleInsulated Tools
Double insulation _ is a design concept used in electric
power tools which eliminates the need for the three wire
grounded power cord and grounded power supply system. It
is a recognized and approved system by Underwriter's
Laboratories, CSA and Federal OSHA authorities.
•Servicing of a tool with double insulation requires care
and knowledge of the system and should be performed
only by a qualified service technician.
•WHEN SERVICING, USE ONLY IDENTICAL
REPLACEMENT PARTS.
POLARIZED PLUGS. If 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. Do not change the plug in any way.
"SAVE THESE INSTRUCTIONS"
Extension Cords
Replace damaged cords immediately. Use of damaged
cords can shock, burn or electrocute.
If an extension cord is necessary, a cord with adequate
size conductors should be used to prevent excessive
voltage drop, loss of power or overheating. The table
shows the correct size to use, depending on cord length
and nameplate amperage rating of tool. If in doubt, use
the next heavier gauge. Always use U.L and CSA listed
extension cords.
Tool's
Am pere
Rating
RECOMMENDED SIZES OF EXTENSION CORDS
120 Volt A.C. Tools
Cord Length in Feet
Cord Size in A.W.G.
3-6
6-8
8-10
10-12
12-16
25 50 100 150
18 16 16 14
18 16 14 12
18 16 14 12
16 16 14 12
14 12 - -
NOTE: The smaller the gauge number, the heavier the cord.
Table of Contents
Page
Safety ......................................................................... 2-6
General Safety Rules for Benchtop Tools .............2-3
Safety Rules for Miter Saws ................................... 3-6
Table of Contents ........................................................ 6
Electrical Requirements ............................................. 7
Getting to Know your Miter Saw ............................ 8-9
Assembly ............................................................... 26-32
Tools needed for Assembly and Alignment ............26
Unpacking and Checking Contents ........................ 28
Installation of Miter Lock Knob ................................ 28
Installation and removal of the Blade ...................... 30
Assembling Dust Elbow and Dust Bag ................... 32
Adjustments .......................................................... 34-44
Blade square to Table (90°) .................................... 34
Blade 45° to Table ................................................... 36
Blade Square to Fence ............................................ 38
Miter Scale and Vernier Scale Usage .....................40
Miter Scale (Vernier) Indicator Adjustment .............42
Crown Molding Detent Adjustment (Bevel) .............42
Page
installation ............................................................ 44, 46
Mounting Applications ............................................. 46
Basic Saw Operations ......................................... 48-54
Body and Hand Position .......................................... 48
Workpiece Support ............................................ 50, 52
Switch Activation ..................................................... 52
Detent Override ....................................................... 54
Sliding Base/Fence Extension ................................ 54
Saw Operations .................................................... 56-72
Miter Cut .................................................................. 56
Bevel Cut ................................................................. 58
Compound Cuts ...................................................... 60
Base Molding ........................................................... 62
Cutting Crown Molding ............................................ 65
Special Cuts ............................................................. 72
Accessories ................................................................ 74
Maintenance and Lubrication ............................ 76, 78
Trouble Shooting ................................................. 80, 82
6

Electrical Requirements
1. Connect this saw to a 120V, 15-amp branch circuit with
a 15-amp time delay fuse or circuit breaker. Using the wrong
size fuse can damage the motor.
2. Fuses may "blow" or circuit breakers may trip frequently
if motor is overloaded. Overloading can occur if you feed the
blade into the workpiece too rapidly or start and stop too
often in a short time.
3. Most motor troubles may be traced to loose or incorrect
connections, overload, low voltage (such as small size wire in
the supply circuit or to overly long supply circuit wire).
Always check the connections, the load and the supply circuit
whenever motor does not work well.
Electric Brake
Your saw is equipped with an automatic electric brake which
is designed to stop the blade from spinning in about five (5)
seconds after you release the trigger switch. It is useful when
making certain cuts in wood where a coasting blade would
result in awide, imprecise cut.
r!'vAV'-_i_ll_[el When electrical power is lost due to
blown fuse or other causes, the motor will gradually slow
down and the braking action is initiated ONLY by the release
of the trigger switch.
The electric blade brake of your miter saw has been designed
for highest degree of reliability, but unexpected
circumstances such as contamination on the commutator
and brushes or failure of motor's components can cause the
brake not to activate. If this condition occurs, turn the saw
"ON" and "OFF" four to five times without contacting the
workpiece. If the tool operates but the brake does not
consistently stop the blade in about five (5)seconds, DO NOT
use saw and have it serviced immediately.
r!'vAV'-_i_ll_[el 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 removing 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.
Wiring Diagram
r!_v*V'-_r`_ll_[e]l This wiring diagram can be used only with the switch (Part No. 2610910020) 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.
Blue _ _ Black (PowerCord)
,vv_ed_ _ _Gray
7

2
1
3
4
27
26
24 23 25
37
30
22
\
\
21
10
16 15
20 17 10 18
ITo avoid injury from accidental
starting, remove plug from power source outlet before
making any adjustments.
1, Carrying Handle
This handle is built into the head assembly for transportation.
2. Arbor Lock
Allows the user to keep the blade from rotating while
tightening or loosening arbor screw during blade replacement
or removal.
3. Ambidextrous Switch
The left or right hand ambidextrous switch must be pressed
to activate the power switch.
14
13
4. Switch Handle
This handle contains the switch. The blade is lowered into
the workpiece by pushing/pulling down on the handle.
5. Power Switch
The power switch used with the ambidextrous switch
energizes the unit.
6. 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.
8

7. Blade
Use only 12" blades with 1" arbor hole.
8. 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.
9. Kerf insert
Minimizes workpiece tear-out.
10. Tool Mounting Pads
The four corners of the saw provide areas to clamp, bolt or
nail the saw to a flat work surface.
11. Detent Override
Allows detent action to be locked out allowing for micro
adjustments to any miter angle.
12. Miter Lock Knob
The miter lock knob locks the miter saw table at any desired
miter angle.
13. Miter Detent Trigger
The trigger releases the table from the detent.
14. Miter Scale
This scale is cast in on the base of the saw. Allows you to
read the miter angles easily.
15. Detents
There are nine (9) miter detents for fast and accurate miter
cuts of common miter angles.
16. Table
Sits in base, provides workpiece support, rotates for desired
miter cuts and rotates the head assembly.
17. Workpiece Clamp Positions
There are six (6) positions around the base for the workpiece
clamp.
18. Base
Provides working surface to support workpiece.
19. Accessory Extension/Stop Holes (Standard Type)
Machined holes that accept the extension/stop accessory.
20. Accessory Pipe Extension/Stop Holes
Machined holes that accept the pipe extension/stop
accessory.
21. Sliding Base
This provides extra support and clamping area for compound
miter cuts.
22. Sliding Fence
Provides maximum height support for the workpiece and
slides to left for easy compound cuts.
23. Lock Pin
The compound miter saw is equipped with a lock pin used to
lock the head assembly in the lower position.
24. Dust Chute Elbow
The dust chute elbow rotates 360° and can accommodate
the dust bag or a 1-1/4" vacuum hose hookup.
25. Chip Deflector
This protects against large chips from entering the upper
guard.
26. Lower Guard Actuation Link
Allows for smooth movement of the lower guard.
27. Upper Blade Guard
Covers upper portion of the blade.
©
30
o
36
28. Blade Wrench
Used for tightening/loosening blade and adjusting bevel
stops. Blade wrench is stored in the switch handle.
29. Bevel Detent Pin (Crown Molding Setting)
Allows you to easily move the head assembly to the bevel
angle of 33.9°.
30. Dust Collection Bag
Attaches to the dust elbow and collects dust to help keep
work area clean.
31. Bevel Lock Handle
The bevel lock handle locks the head assembly at a desired
bevel angle. Handle ratchets for use in tight spaces.
32. 45° Bevel Stop
Adjustable stop for a quick and accurate 45° bevel index.
33. 0° Bevel Stop
Adjustable stop for a quick and accurate 0° bevel index.
34. Bevel Scale
This scale is cast in on the saw. Allows you to read the bevel
angles easily.
35. Hex Wrench
Used to adjust sliding base. Hex wrench is stored in the left
rear base.
36. Brush Caps
These caps keep the motor brushes in position and provide
easy access for inspecting and replacing brushes.
37. Quick Action Clamp
Provides fast clamping of workpiece.
FOR CONTiNUATiON OF ENGLISH SEE PAGE 26
9

blessures.
S curit
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•Ne laissez pas J'outiJen marche, sans surveillance, mettez
hers tension. Ne laissez pas I'outil avant qu'il soit & I'arr_,t
complet.
•RENDEZL'ATEUERA L'rtPREUVEDES ENFANTS_,I'aide de
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preuve de discernement en utiJisantun outil _Jectfique. Un
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m(_dicamentspeut s'av@er dangereux durant I'utilisation d'un
outil (_lectrique.
•Portez des v_tements convenabJes. Ne portez pas de
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Ionguesau-dessusdu coude.Le port de gantsen caoutchoucet
de chaussures_,semelleantid@apanteest recommand(_si vous
travaillez_,I'ext@ieur.
•ftvitez Ja raise en marche accidenteJJe.Assurez-vousque
J'interrupteur est _ J'arr_t avant de hrancher.Le transport de
I'outil avec le doigt sur I'interrupteur ou le branchementd'outils
dentI'interrupteurestb,la positiondemarcheinvitelesaccidents.
• Enlevezlos cJ_sde r_gJageet autres cl_s avant de mettre
J'outiJ en marche. Une cl(_qui est laiss(_efix(_e_,une piece
rotativedeI'outil seraprojet@.
• TravaiJJezavec aplomb et _quiiibre _ tout moment, cequi aide
mieux contrSJerJ'outiJdartsJescasimpr_vus.
•Ne montez pas sur J'outiJni sur son supped. Des bJessures
gravespeuvent#,trecaus@sencasde basculementdeI'outil ou
de contactaccidentelavec I'outil de coupe. Neconservezpas de
mat@iaux sur ou b,proximit_ de I'outil de sorte qu'il soit
n@essaire de monter sur I'outil ou son support pour les
atteindre.
UtiJisezJ'_quipementde s_curit_.Podeztoujours des Junettes
coquesJat_raJes.Un masqueanti-poussi_re,des chaussures
de s_curit_, un casquedur ou des prot_ge-oreiiiesdoivent _,tre
utiiis(_s si ia situation i'exige.Les lunettes de tous los jours
comportent uniquementdes verres r(_sistantaux chocs. Ce NE
SeNTPASdes lunettesdes@urit_.
,,CONSERVEZCESINSTRUCTIONS,,
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