MF 26 cc - Milling machine Mafell - Free user manual and instructions

Product Type	Plunge saw (grooving)
Brand	Mafell
Model	MF 26 cc
Dimensions (L x W x H)	250 x 330 x 215 mm
Weight (without cable or guide)	5.0 - 6.6 kg
Service Voltage	230 V AC / 110 V AC / 120 V AC
Frequency	50 / 60 Hz
Power Consumption (continuous)	1400 W
No-load Speed (range)	3600 - 6250 min⁻¹
Speed Adjustment	6 levels (via thumbwheel)
Max Cutting Depth	26 mm
Max Tool Diameter	122 mm
Mounting Bore	20 mm
Suction Sleeve Diameter	35 mm
Sound Pressure Level (LpA)	96 dB(A)
Sound Power Level (LwA)	104 dB(A)
Vibration (typical value)	3.6 m/s²
Protection Class	II
Safety Devices	Fixed upper protective guard, movable lower guard, wide base, insulated handles, automatic brake
Intended Use	Solid wood, wood-based panels, plaster, composite aluminum, laminate
Standard Equipment	Saw blade, position indicators, parallel guide, service tools, suction hose, splinter guard, case or box, manual
Optional Accessories	Guide rails, angle stop, guide roller, notching unit, variable pitch grooving attachment, special cutters
Maintenance and Cleaning	Regular cleaning of adjustment and guide devices; special grease for bearings; store in dry conditions
Repairability	Original Mafell spare parts and accessories available; exploded diagram on website

Frequently Asked Questions - MF 26 cc Mafell

How to change the tool on the Mafell MF 26 cc?

Unplug the mains plug. Remove the chip deflector. Open the protective guard by pressing the pusher and lock lever. Loosen the flange screw using the hex key. Replace the tool respecting the direction of rotation. Tighten the flange and close the guard. See the manual for details.

How to adjust the cutting depth?

The cutting depth can be adjusted from 0 to 26 mm in 1 mm steps using the depth stop (11). For intermediate dimensions, turn the cylindrical screw (12): one turn corresponds to 1 mm, one mark on the screw head to 0.1 mm.

What materials can be machined with the MF 26 cc?

Solid wood, wood-based panels (chipboard, MDF, blockboard), plaster/gypsum board, composite aluminum panels and laminate. Use the appropriate tool (saw blade, plasterboard cutter, etc.) according to the material.

How to use the guide rail?

Place the machine on the guide rail so that the groove in the base engages with the spring. Set the cutting depth indicator to the upper position. Use clamps to fix the rail to the workpiece. The position indicator allows alignment of the rail with the marked line.

What to do if the machine stops during cutting?

This may be due to a mains failure (check fuses) or overload (reduce feed speed). The electronic system protects the motor in case of overload; release the switch and restart with reduced feed.

How to adjust the rotation speed?

Use the thumbwheel (9) to adjust the speed gradually from 3600 to 6250 min⁻¹ in 6 levels. Adapt the speed to the material: levels 1-2 for PVC, composite aluminum; levels 3-6 for wood and panels.

What safety devices are integrated?

Fixed upper protective guard, movable lower guard (automatic closing), anti-tip wide base, insulated handles, automatic brake (stop in 5 s), restart lock. Never remove these devices.

How to maintain the grooving machine?

Clean the adjustment and guide devices regularly. The ball bearings are lubricated for life; after long use, have them serviced by an authorized center. Use Mafell special grease (ref. 049040) for lubrication points.

What accessories are available for the MF 26 cc?

Guide rails (F80 to F310), angle stop, guide roller, notching unit MF-SE3, variable pitch grooving attachment MF-VN25, cutters for plasterboard and composite aluminum, suction hose, and guide kits.

How to avoid burn marks on the cut?

Use a sharp tool suitable for the material. Reduce feed speed if necessary. Ensure the chip outlet is not blocked and connect an external vacuum for extended work.

USER MANUAL MF 26 cc Mafell

Exterior view of a mechanical device with black and gray components (no visible text or symbols)

WARNUNG

Please read all safety instructions and directions. Failure to comply with the safety instructions and directions can cause electric shock, fire and/or serious injuries. Please retain all safety instructions and directions for future reference.

AVERTISSEMENT

Industrial cutting machine with visible blade and mounting base, no text or symbols present

MAF01990/a

Mechanical device with labeled parts (9 and 20), no visible text or symbols beyond labels

MAF01991/a

6 5 23 38 4

MAF01992/a

3 2 8 7 11 12 5

MAF01993/a

42 6 24

MAF01994/a

29 10 39

MAF01996/a

30 32 34 33 31 8

MAF01997/a

36 34 37 35

MAF01998/a

44 10

MAF02006/a

GB - EC Declaration of Conformity

We herewith confirm that the machine MF 26 cc complies with the EU directives quoted. The standards listed were used for design and construction.

Empowered person for the configuration of the technical documents: Mafell AG

1	Signs and symbols	22
2	Product information	22
2.1	Manufacturer's data	22
2.2	Machine identification	22
2.3	Technical data	23
2.4	Emissions	23
2.5	Scope of supply	23
2.6	Safety devices	24
2.7	Use according to intended purpose	24
2.8	Residual risks	24
3	Safety instructions	25
4	Setting / Adjustment	26
4.1	Mains connection	26
4.2	Chip extraction	26
4.3	Cut quality	26
4.4	Secure machine against tilting	26
4.5	Selection of tools	26
4.6	Tool change to saw blade, plasterboard milling cutter or aluminium compound milling cutter	26
4.7	Installation chip deflector	27
4.8	Tool change to slitting unit or adjustable groove cutter	27
4.9	Setting the milling width or assembly of the adjustable groove cutter	27
4.10	Assembly of the slitting unit	28
4.11	Reversible knife change and setting "Adjustable groove cutter"	28
4.12	Reversible knife change and setting "Plasterboard milling cutter"	28
4.13	Aluminium compound milling cutter	29
5	Operation	29
5.1	Initial operation	29
5.2	Switching on and off	29
5.3	Incising the guide rail (special accessories)	29
5.4	Cutting depth adjustment	30
5.5	Grooves	30
5.6	Handling	30
5.7	Plunge cuts	30
5.8	Working according to marking	30
5.9	Working with the parallel stop	30
5.10	Working with the roller edge guide	31
5.11	Working with guide rail	31
5.12	Working with position indicator	31
6	Service and maintenance	31
6.1	Storage	31

7 Troubleshooting....32
8 Optional accessories 33
9 Material selection / tool selection 34
10 Exploded drawing and spare parts list 34

1 Signs and symbols

This symbol is found in all places where you will find information for your safety.

Non-compliance with these instructions may result in very serious injuries.

This symbol indicates a potentially hazardous situation.

If this situation is not avoided, the product or objects in its vicinity may get damaged.

This symbol indicates tips for the user and other useful information.

2 Product information

for machines with item No. 917801, 917802, 917804, 917820, 917823, 917825, 917840, 917843, 917845, 917880, 917881, 917882, 917883, 917885, 917888

2.1 Manufacturer's data

MAFELL AG, Beffendorfer Straße 4, D-78727 Oberndorf / Neckar, Phone [phone], Fax [phone], e-mail: [e-mail]

2.2 Machine identification

All details required for machine identification are available on the attached rating plate.

Protection class II

CE symbol to document compliance with the basic safety and health requirements according to Appendix I of the Machinery Directive.

For EU countries only

Do not dispose of electric tools together with household waste material!

In accordance with the European directive 2002/96/EC on waste electrical and electronic equipment and transposition into national law, obsolete electrical tools must be collected separately and recycled in an environmentally-compatible manner.

To reduce the risk of injury, please read the operating instructions.

2.3 Technical data

Operating voltage	230 V AC	110 V AC	120 V AC
Mains frequency	50 Hz	50 Hz	60 Hz
Input power continuous operation	1400 W	1400 W	1400 W
Power consumption continuous operation	7,0 A	10,0 A	10,0 A
Speed during idling	3600 - 6250 rpm
Cutting depth	0 - 26 mm (0 – 1 1/32 in.)
Tool diameter	max. 122 mm (4 51/64 in.)
Tool mounting hole	20 mm
Hose connector diameter	35 mm (1 3/8 in.)
Weight without mains cable, without parallel guide fence	5.0 - 6.6 kg (11 – 14.5 lbs)
Dimensions (W x L x H)	250 x 330 x 215 mm (9 27/32 x 13 x 8 15/32 in.)

2.4 Emissions

The declared noise emission values have been measured in accordance with DIN EN 62841-1 and may be used for comparing the tool with another and also in a preliminary assessment of exposure.

Danger

The noise emissions during actual use of the power tool can differ from the declared values depending on the ways in which the tool is used especially what kind of workpiece is processed.

Always wear hearing protection, even when the power tool is running idle in addition to the trigger time!

2.4.1 Noise emission specifications

Noise emission values determined according to EN 62841:

Sound pressure level	L_PA = 96 dB (A)
Uncertainty K	_PA = 3 dB (A)
Sound power level L	_WA = 104 dB (A)
Uncertainty	K_WA = 3 dB (A)

The noise level measurement was carried out with a saw blade, adjustable groove cutter, slitting unit, plasterboard and aluminium compound milling cutter supplied with the machine as standard equipment.

2.4.2 Vibration specifications

The typical hand-arm vibration is 3.6 m/s ^2 .

2.5 Scope of supply

Groove-cutting machine MF26cc complete with:

1 milling tool
1 saw blade (for MAX aluminium with 40 teeth, for MAX construction, GF and KSS wood with 24 teeth)
2 position indicators
1 parallel stop cpl.
2 operating tools

1 hose connector
1 chip deflector (only for model MAX aluminium)
1 guide rail (for models 917804, 917880, 917881, 917883, 917885)
1 carrying case (for models 917801, 917820, 917823, 917825, 917802, 917840, 917843, 917845)
1 transport case (for models 917804, 917880, 917881, 917882, 917883, 917885, 917888)
1 operating manual
1 folder "Safety instructions"

2.6 Safety devices

Danger

These devices are required for the machine's safe operation and may not be removed or rendered inoperative.

Before operating the machine, check the safety devices for function and possible damage. Do not use the machine with missing or ineffective safety devices.

The machine is equipped with the following safety devices:

• Upper stationary saw guard
• Lower retractable saw guard
• Large base plate
• Handles
• Index mechanism and brake
• Hose connector

2.7 Use according to intended purpose

The groove-cutting machine is exclusively suited for longitudinal and cross cutting as well as for milling solid wood, panel materials such as chip board, coreboard, MDF board, gypsum plasterboard, aluminium compound panels and laminate panels.

Special use of the tools:

• The saw blade is exclusively suited for processing wood, plaster board panels, aluminium compound and laminate panels.
• The slitting unit (special accessories) is exclusively suited for processing wood and plaster board panels.

• The adjustable groove cutter is exclusively suited for machining wood.

• The plasterboard milling cutter is exclusively suited for processing wood and plaster board panels.

• The aluminium compound milling cutter is exclusively suited for machining aluminium compound panels.

Only use the approved tools. Our tools are manufactured according to EN 847-1. Any other use than described above is not permissible. The manufacturer cannot be held liable for any damage arising from such other use.

To use the machine as intended, comply with the operating, maintenance and servicing conditions prescribed by Mafell.

2.8 Residual risks

Danger

Even if used in accordance with its intended purpose and despite conforming with the safety instructions, residual risks caused by the intended use that can lead to health consequences will always remain.

• Touching the part of the saw blade that protrudes below the workpiece when cutting.
• Touching of turning parts from the side: Tool, clamping flange and flange screw.
• Machine backlash if the blade gets stuck in the workpiece.
• Breakage and hurling out of the tool or parts of the tool.
• Touching live parts with the housing open and the mains plug not removed.
• Hearing can be impaired when working for long periods without ear protectors.
• Emission of hazardous dusts during longer lasting operation without extraction.

3 Safety instructions

Danger

Always observe the following safety instructions and the safety regulations applicable in the respective country of use!

Also read the safety instructions in the enclosed booklet "Safety instructions".

General instructions:

• Children and adolescents must not operate this machine. This rule does not apply to young persons receiving training and being supervised by an expert.
• Never work without the protection devices prescribed for the respective operating sequence and do not make any changes to the machine that could impair safety.
• When operating the machine outdoors, use of an earth-leakage circuit-breaker is recommended.
• Damaged cables or plugs must be immediately replaced. Replacement may only be carried out by Mafell or an authorised MAFELL service workshop in order to avoid safety hazards.
• Avoid sharp bends in the cable. Especially when transporting and storing the machine, do not wind the cable around the machine.

Do not use:

• Cracked tools or tools that have changed their shape.
• Tools made of high speed steel (HSS tools).
• Blunt tools due to the excessive engine load.
• Tools that are not suitable for the tool speed during idling.

Instructions on the use of personal protective equipment

- Always wear your personal protective equipment whenever you are working with the machine. Hearing protection, dust mask, protective goggles and protective gloves.

Instructions on operation:

• Keep your hands away from the cutting range and the tool. With your other hand, support the supplementary handle or the motor casing.

• Do not reach under the workpiece.

• Adapt the cutting depth to the workpiece thickness.

• Never support the workpiece in your hand or over your leg. Secure the workpiece against a sturdy support.
• Only hold the device by its isolated handle surfaces when carrying out work during which the cutting tool could hit hidden power cables or its own connection cable.
• Always use a limit stop or a straight edge guide for longitudinal cutting.
• Always use tools of the correct size and with matching mounting hole (e.g. star-shaped or round).
• Never use damaged or incorrect tool washers or screws.
• Hold the machine with both hands and bring your arms into a position where you are able to resist the backlash forces. Always keep to the side of the tool, never bring the tool in line with your body.
• Release the on/off switch if the tool is stuck or machining is interrupted for another reason. Keep the machine steady in the material until the tool has come to a complete standstill. Never try to remove the machine from the workpiece or pull it backwards as long as the tool is moving or could recoil.
• If you want to restart a tool that is stuck in the workpiece, centre the tool in the tool gap and check whether the teeth of the tool have got jammed in the workpiece.
• Support large plates to reduce the risk of a backlash caused by a jammed tool.
• Do not use any blunt or damaged tools.
• Be especially careful when making a "plunge cut" into a concealed area, e.g. into an existing wall.
• Prior to every use, check whether the saw guard is closing properly. Do not use the groove-cutting machine if the saw guard is unable to move freely and does not close immediately. Never clamp or tie down the saw guard in an open position.
• Check the state and function of the spring for the saw guard. Have the machine serviced prior to use if saw guard and spring do not work properly.

• When carrying out plunge cuts, always secure the base plate of the machine against dislocation to the rear.

• Do not place the groove-cutting machine onto the workbench or floor without the saw guard covering the tool.

• Examine the workpiece for foreign objects. Do not saw or mill into steel parts.
• Use the chip deflector when milling aluminium compound panels to avoid damage to machine and material.

Instructions on service and maintenance:

• Regularly cleaning the machine, especially the adjusting devices and guides, constitutes an important safety factor.
• Only original MAFELL spare parts and accessories may be used. Otherwise the manufacturer will not accept any warranty claims and cannot be held liable.

4 Setting / Adjustment

4.1 Mains connection

Prior to commissioning make sure that the mains voltage complies with the operating voltage stated on the machine's rating plate.

4.2 Chip extraction

Danger

Substances that are harmful to health must be taken up with an M-suction device.

Connect the machine to a suitable external dust extractor during all work generating a considerable amount of dust. The air velocity must be at least 20 m/s (65.6 ft / sec.).

The internal diameter of hose connector 1 (Fig. 1) is 35 mm (1 3/8 in.).

4.3 Cut quality

Use a sharp tool to achieve a good cut quality. Select a tool from the list in chapter 4.5 according to the material.

4.4 Secure machine against tilting

The cover of the groove-cutting machine is equipped with a glider as support against tilting. The glider must be turned for the respective application (with or without rail).

• Unscrew the fastening screw 27 (Fig. 1) using the Allen key 4 (Fig. 2).
• Rotate the glider 28 (Fig. 1) around the fastening screw until the printed diagram on the glider (right) corresponds to the desired application (with or without rail). (Adjusting screws 26 (Fig. 1), which can be adjusted with the Allen key 4 (Fig. 2) are located at the bottom / top side of the glider for fine adjustment of the glider).
  • Retighten the fastening screw 27 (Fig. 1).

4.5 Selection of tools

• Saw blade-TCT ∅ 120 x 1.8 x 20 mm (4 47/64 x 5/64 in. x 20 mm), 12 teeth
• Saw blade-TCT ∅ 120 x 1.8 x 20 mm (4 47/64 x 5/64 in. x 20 mm), 24 teeth
• Saw blade-TCT ∅ 120 x 1.8 x 20 mm (4 47/64 x 5/64 in. x 20 mm), 40 teeth
• Saw blade-TCT ∅ 120 x 1.2 x 20 mm (4 47/64 x 3/64 in. x 20 mm), 40 teeth
• Slitting unit MF-SE3
• Adjustable groove cutter MF-VN25
• Plasterboard milling cutter MF-GF90/15
• Aluminium compound milling cutter MF-AF90

See also the table in chapter 9.

4.6 Tool change to saw blade, plasterboard milling cutter or aluminium compound milling cutter.

Danger

Pull the power plug during all service work.

The chip deflector must be unscrewed prior to a tool change.

The protective hood cannot be opened as long as the chip deflector is installed.

• Using the Allen key 4 (bracket Fig. 2), unscrew the countersunk screw with chip deflector 44 (Fig. 11).
• To change the tools, place the machine with the marking 17 (Fig. 1) or splinter guard 38 (Fig. 4) on the edge of a support surface so that the cover can tilt across the edge when it is opened.
• To fold the saw guard cover 23 (Fig.4) down on the side, press push-button 2 (Fig. 5). With depressed push-button, pull locking lever 3 upwards. Pulling

the locking lever automatically locates the shaft in position and locks the gearshift lever 8 (Fig. 5).

• Using the Allen key 4 (brackets Fig. 2), release the flange screw 5 (Fig. 4) counter clockwise. Pull off the slitting unit or adjustable groove cutter to the front.
• Push the rear flange 29 (Fig. 8) onto the shaft (if not present).
• The clamping flanges must be free of adhering parts.
• Place the saw blade, the plasterboard milling cutter or the aluminium compound milling cutter onto the rear flange 29 (Fig. 8).
• When fitting the tool, pay attention to the sense of rotation (see direction of arrow on the casing and on the cover).
• Push the clamping flange and flange screw onto the tool.
• Tighten the flange screw by turning it clockwise with the Allen key.
• Close the saw guard cover. To this end, close the cover and press the locking lever 3 (Fig. 5) downwards.

4.7 Installation chip deflector

The chip deflector must always be fitted when milling aluminium compound panels. This prevents damage to machine and material.

Follow the procedure below:

- Using the Allen key 4 (bracket Fig. 2), fasten the chip deflector 44 (Fig. 10) with the countersunk screw.

4.8 Tool change to slitting unit or adjustable groove cutter

Danger

Pull the power plug during all service work.

The chip deflector must be unscrewed prior to a tool change. The protective hood cannot be opened as long as the chip deflector is installed.

- To change the tools, place the machine with the marking 17 (Fig. 1) or splinter guard 38 (Fig. 4) on

the edge of a support surface so that the cover can tilt across the edge when it is opened.

• To fold the saw guard cover 23 (Fig.4) down on the side, press push-button 2 (Fig. 5). With depressed push-button, pull locking lever 3 upwards. Pulling the locking lever automatically locates the shaft in position and locks the gearshift lever 8 (Fig. 5).
• Using the Allen key 4 (brackets Fig. 2) release the flange screw 5 (Fig. 4) counter clockwise.
• Remove the flange 6 (Fig. 4) and the flange screw 5 (Fig. 4).
• Remove the rear flange 29 (Fig. 8) (if present).
• Push the slitting unit or adjustable groove cutter onto the shaft.
• Tighten the flange screw 5 (Fig. 4) by turning it clockwise with the Allen key.
• Close the saw guard cover. To this end, close the cover and press the locking lever 3 (Fig.5) downwards.

4.9 Setting the milling width or assembly of the adjustable groove cutter

The adjustable groove cutter 30 (Fig. 9) is a reversible knife adjustable groove cutter, which can be adjusted to milling widths between 15.4 and 25.0 mm (39/64 – 63/64 in.). Spacers in the following thickness are included with the adjustable groove cutter: 5 / 2 / 1 / 0.5 (2x) / 0.3 (2x) / 0.1 (approx. 13/64, 5/64, 3/64, 1/32 - 2x, 1/64 – 2x, 1/128 in.).

With these you can create interim widths in 0.1 - 0.2 mm (0.004 - 0.008 in.) steps.

Proceed as follows:

• First compile the required adjustable groove cutter width with the enclosed spacers (the adjustable groove cutter without spacers has a groove width of 15.4 mm (39/64 in.)).
• To assemble the individual parts of the adjustable groove cutter, first the spacers that are not required are pushed onto the front flange 31 (Fig. 9). Attention must be paid that the largest spacer thickness is always the first to rest on the clamping flange.
• Afterwards, first place the front part of the adjustable groove cutter (the side with the lettering) onto the flange.
• Then place the required spacers onto the flange.
• Fit the rear part of the adjustable groove cutter onto the flange and press the entire unit together (possibly while twisting it slightly) until the front flange engages with the rear flange.

The adjustment range specified on the adjustable groove cutter may on no account be exceeded. Ensure that all the enclosed spacers are fitted at all times.

4.10 Assembly of the slitting unit

• Take the rear mounting of the slitting unit (star-shaped opening in the bore) with the short diameter into your left hand.
• Push the saw blade onto the mounting diameter such that the saw teeth above the mounting are pointing towards you.
• Push a spacer onto the mounting.
• Repeat the procedure with saw blade and spacer in the same sequence twice more.
• Fit the front flange with the integrated flange screw into the bore and twist the flange while exerting a slight pressing movement until the flange engages.

4.11 Reversible knife change and setting "Adjustable groove cutter"

The adjustable groove cutter 30 (Fig. 9) is equipped with 4 carbide reversible knives 32 and 4 carbide precutters 33. If the blades are becoming blunt, you can turn the reversible knife 32 (Fig. 9) thrice and the reversible knife 33 (Fig. 9) twice. After that, new original reversible knives must be fitted!

Proceed as follows:

• Dismantle the adjustable groove cutter 30 (Fig. 9) from the machine as described in 4.8.
• Unscrew the countersunk screws 34 (Fig. 9) using the torx screw driver.
• Clean all parts and the knife chambers of the adjustable groove cutter.
• Turn or replace the reversible knives 32 and 33.
• Fasten the reversible knives with the countersunk screws and retighten these with the torx screw driver (4 Nm).

The two parts have been inserted correctly if the rear of a knife edge is resting against the carrier body and the countersunk screw can be screwed in that far that the surface of the countersunk screw is located below or on the same level as the surface of the reversible knife (see Fig. 9). The radial blade protrusion of max. 1.1 mm (3/64 in.) is thus guaranteed.

4.12 Reversible knife change and setting "Plasterboard milling cutter"

The plasterboard milling cutter 35 (Fig. 10) is equipped with 2 carbide reversible knives (4-blade) and 4 carbide reversible knives (3-blade). If the blades are becoming blunt, you can turn the reversible knife 36 (Fig. 10) twice and the reversible knife 37 (Fig. 10) thrice. After that, new original reversible knives must be fitted!

Proceed as follows:

• Dismantle the adjustable groove cutter 35 (Fig. 10) from the machine as described in 4.7.
• Unscrew the countersunk screws 34 (Fig. 10) using the torx screw driver.
• Clean all parts and the knife chambers of the plasterboard milling cutter.
• Turn or replace the reversible knives 36 and 37.
• Fasten the reversible knives with the countersunk screws and retighten these with the torx screw driver (4 Nm).

The two parts have been inserted correctly if the rear of a knife edge is resting against the carrier body and the countersunk screw can be screwed in that far that the surface of the countersunk screw is located below or on the same level as the surface of the reversible knife (see Fig. 10). The radial blade protrusion of max. 1.1 mm (3/64 in.) is thus guaranteed.

4.13 Aluminium compound milling cutter

Aluminium compound milling plates cannot be turned as they are soldered in. (A blunt tool must be reground).

5 Operation

Always wear your personal protective equipment whenever you are working with the machine.

5.1 Initial operation

Personnel entrusted to work with the machine must be made aware of the operating instructions, calling particular attention to the chapter "Safety instructions".

5.2 Switching on and off

- Switching on: First unlock the switch-on lock by pressing the locking lever 7 (Fig. 5). Then, keeping the locking lever depressed, activate the gearshift lever 8.

As this is a switch without locking device, the machine will only run for as long as this gearshift lever is pressed.

The built-in electronic system provides for jerk-free acceleration when the machine is switched on and under load readjusts the speed to the fixed setting.

In addition, this electronic system reduces the motor output in case of an overload, i.e. the tool stops. Switch the machine off then. Then switch the machine on again and continue sawing at a reduced feed speed.

The setting wheel 9 (Fig. 3) can be used to adjust the tool speed in a continuously variable manner between 3600 and 6250 rpm.

Level Speed rpm
1 3600
2 4130
3 4660
4	5190
5	5720
6 6250

Material groups

- PVC, plexiglass, PA, aluminium compound - Level: 1 - 6

- Hardwood, softwood, plywood - Level: 3 - 6

- Coated panel materials - Level: 4 - 6

- Plaster - Level: 3 - 5

- Switching off: To switch off, release the gearshift lever 8. The built-in automatic brake limits the slowing time of the tool to approx. 5 s. The switch-on lock is automatically reactivated and secures the groove-cutting machine against accidental switch-on.

5.3 Incising the guide rail (special accessories)

Danger Initial start-up

Trim the splinter guard 38 (Fig. 4) with the saw blade prior to initial start-up:

• Place the rail onto a level support.
• Put down the machine at the start of the rail with the groove 24 (Fig. 6) in the base plate on the spring of the rail.
• Set the cutting depth to approx. 3 mm (1/8 in).
• Switch on the machine and slide it evenly in cutting direction across the entire length. The newly formed cut edge on the splinter guard serves as tracing edge for the saw blade, the adjustable groove cutter and the slitting unit.
• Place the rail onto the workpiece.
• Push it against the workpiece and align it with the marking. In order to fix the rail, clamp the rail with the two screw clamps (special accessories) 39 (Fig. 8).
• Set the cutting depth at the machine.
• Switch on the machine and slide it evenly in cutting direction.
• Do not clean the rail with solvents – the anti-skid coating could get damaged.

5.4 Cutting depth adjustment

The cutting depth can be set between 0 and 26 mm (0 and 1 1/32 in.), graded in 1 mm (3/64 in.) steps.

Proceed as follows:

• Adjust the indicator 10 (Fig. 8) by turning. The top position is for working with guide rail, the bottom position for working without guide rail.
• Set the cutting depth with the depth stop 11 (Fig. 5) according to the scale. The limit stop has a 1 mm (3/64 in.) latching mechanism.
• To set intermediate measures, turn the cylinder head bolt 12 (Fig. 5) with the Allen key 4 (brackets Fig. 2). One turn corresponds to 1 mm (3/64 in.), one scale line on the screw head corresponds to 0.1 mm (1/128 in.).

5.5 Grooves

Set the desired cutting depth according to chapter 5.4.

Carry out groove cutting using a guiding device. Wider grooves are achieved by laterally offsetting the guiding device from the right to the left.

5.6 Handling

Danger

The groove-cutting machine is not suitable for freehand guidance. The use of parallel stop, roller edge guide, KSS rail or F-rail guide is compulsory. In case of the KSS model, place the workpiece onto the support frame in a stable manner.

5.7 Plunge cuts

Danger

Risk of backlash during plunge cuts! Prior to plunging, place the machine with the rear edge of its base plate against a limit stop fastened on the workpiece. When using the guide rail (special accessories) you must fasten the limit stop available as special accessory on the guide rail. Keep a firm hold on the machine handle during plunging and push the saw lightly forward!

5.8 Working according to marking

The base plate has two fixed marking indicators 17 and 25 (Fig. 1). Marking indicator 25 corresponds to the centre of the plasterboard and aluminium compound milling cutter. Marking indicator 17 corresponds to the inside of the saw blade, adjustable groove cutter and slitting unit.

• Always use a guiding device.
- Secure the workpiece against dislocation and arrange the workpiece supports such that the tool underneath the workpiece is running freely (in case of a severing cut).
- Hold the machine by the handle and place the front part of the base plate onto the workpiece.
- Switch on the groove-cutting machine (see 5.2). Plunge to the set cutting depth and slide the machine evenly forward in the direction of the cut.
• After the end of the cut, switch off the groove-cutting machine by releasing the gearshift lever 8 (Fig. 5).
- While it is resting on the workpiece, pull the machine back into home position and in this position remove it from the workpiece. Proceeding in this manner ensures that the retractable saw guard is completely closed.
- The saw unit tilts back into the top locked position.

5.9 Working with the parallel stop

The parallel stop 18 (Fig. 2) is used to work parallel to an already existing edge. The limit stop can be attached to the left or right of the machine. The cutting range on the right-hand side amounts to approx. 170 mm (6 45/64 in.) and on the left-hand side to approx. 345 mm (13 37/64 in.).

• When working with the parallel stop, set the cutting depth indicator 10 (Fig. 8) by turning it into the bottom position (without rail).
• The rods of the parallel stop have a scaling, which refers to the left-hand side of the saw blade.
• You can adjust the cutting width after releasing the wing screws 19 (Fig. 2) by moving the limit stop accordingly and afterwards retightening the wing screws.

In addition, by simply turning it around, the parallel stop can also be used as double support to improve groove-cutting machine guidance (guide surface for the workpiece edge is pointing upwards). Now the machine can be guided along a lath that is fastened on the workpiece.

5.10 Working with the roller edge guide

The parallel stop 20 (Fig. 3) is used to work parallel to an already existing edge. The limit stop can be attached to the left or right of the machine. The cutting range on the right-hand side amounts to approx. 0 - 100 mm (0 - 3 15/16 in.) and on the left-hand side to approx. 23 - 230 mm (29/32 - 9 1/16 in.).

• When working with the roller edge guide, set the cutting depth indicator 10 (Fig. 8) by turning it into the bottom position (without rail).
• The rods of the parallel stop have a scaling, which refers to the left-hand side of the saw blade.
• You can adjust the cutting width after releasing the wing screws 19 (Fig. 2) by moving the limit stop accordingly and afterwards retightening the wing screws.

Now the machine can be guided along a narrow workpiece running below the base plate.

5.11 Working with guide rail

• Place the machine onto the guide rail such that the groove 24 (Fig. 6) of the base plate rests above the spring and is guided by it.
• Set the cutting depth indicator 10 (Fig. 8) into the top position by turning (with rail). Thus, the scale can also be used with the rail.

5.12 Working with position indicator

Use the position indicator to align the guide rail to a centre marking of the guide groove. It is included with the machine or tools (for plasterboard milling cutter and aluminium compound milling cutter).

Proceed as follows:

• Fit the position indicator 42 (Fig. 6) onto the rib of the guide rail.
• Move the position indicator on the rail up to the marking.
• Move the rail with position indicator until the front (red edge) of the marking indicator agrees with the marking.
• Place the machine onto the rail (the tool is now aligned with the centre of the marking).
• Set the required milling depth and machine the workpiece.

6 Service and maintenance

Danger

Pull the power plug during all service work.

MAFELL machines are designed to be low in maintenance.

The ball bearings used are greased for life. When the machine has been in operation for a longer period of time, we recommend to hand the machine in at an authorised MAFELL customer service shop for inspection.

Only use our special grease, order No. 049040 (1 kg tin) for all greasing points.

6.1 Storage

Clean the machine thoroughly if the machine is not used for a longer period of time. Spray blank metal parts with a rust-proofing agent.

7 Troubleshooting

Danger

Determining the causes for existing defects and eliminating these always requires increased attention and caution. Pull the mains plug beforehand!

Some of the most frequent defects and their causes are listed in the following chart. In case of other defects, contact your dealer or the MAFELL customer service.

Defect	Cause	Elimination
Machine cannot be switched on	No mains voltage	Check power supply
	Mains fuse defective	Replace fuse
	Carbon brushes worn	Take the machine to a MAFELL customer service shop
Machine stops while cutting is in process	Mains failure	Check mains back-up fuses
	Machine overloaded	Reduce feed speed
Tool jams when advancing the machine	Feed rate too fast	Reduce feed speed
	Blunt tool	Release the switch immediately. Remove machine from the workpiece and exchange tool
	Tension in the workpiece
	Poor machine guidance	Use parallel stop
	Uneven workpiece surface	Straighten the surface
Burn marks on the cut surfaces	Tool unsuitable or too blunt for the work process	Replace tool
Chip ejection blocked	Wood is too damp	Clean chip ejection
	Extended operation without extraction	Connect to an external extraction, e.g. portable dust extractor

8 Optional accessories

• Saw blade carbide ∅ 120 x 1.8 x 20 mm, 12 teeth (longitudinal cut) Order No. 092560
• Saw blade carbide 120 x 1.8 x 20, 24 teeth (longitudinal and cross cuts) Order No. 092558
• Saw blade carbide 120 x 1.8 x 20, 40 teeth (cross cut) Order No. 092559
• Saw blade carbide ∅ 120 x 1.2 x 20 mm, 40 teeth (laminate) Order No. 092578
• Guide rail F 80, 800 mm long Order No. 204380
• Guide rail F 110, 1100 mm long Order No. 204381
• Guide rail F 160, 1600 mm long Order No. 204365
• Guide rail F 210, 2100 mm long Order No. 204382
• Guide rail F 310, 3100 mm long Order No. 204383
• Sliding bevel segment F-WA Order No. 205357

- Accessories for guide rail:

• Screw clamp F-SZ180MM (2 pieces) Order No. 207770
• Connecting piece F-VS Order No. 204363
• Rail bag 160 Order No. 204626

- Rail bag kit F80/160 with sliding bevel segment consisting of: F80 + F160 + Order No. 204749 connecting piece + sliding bevel + 2 screw clamps + rail bag

- Rail bag kit F160/160 consisting of: 2 x F160 + connecting piece + 2 screw Order No. 204805 clamps + rail bag

- Backlash stop F-RS Order No. 202867

- Roller edge guide MF-UA, cpl. Order No. 206073

- Slitting unit MF-SE3 Order No. 206072

- Adjustable groove cutter MF-VN25 Order No. 206074

• Reversible TCT knife (4 pieces required) Order No. 206064
• Chamfer knife (4 pieces required) Order No. 201930

- Plasterboard milling cutter MF-GF45 with 2 position indicators Order No. 205562

- Chamfer knife (6 pieces required) Order No. 201930

- Plasterboard milling cutter MF-GF90/15 with 2 position indicators Order No. 206590

– Reversible TCT knife (2 pieces required) Order No. 206067
– Chamfer knife (4 pieces required) Order No. 201930

- Aluminium compound milling cutter MF-AF90 with 2 position indicators + chip Order No. 206076 deflector

- Aluminium compound milling cutter MF-AF135 with 2 position indicators + chip Deflector Order No. 206600

- Suction hose LW 35, 4 m antistatic Order No. 093717

- guiding device M (only for wood - KSS) Order No. 208170

- guiding device ML (only for wood - KSS) Order No. 204378

• End caps packed F-EK Order No. 205400
• Adhesive profile packed F-HP 6.8M Order No. 204376
• Splinter guard packed F-SS 3.4M Order No. 204375

9 Material selection / tool selection

Materials Tools	Wood / wood-based material boards	Plaster / plasterboard	Aluminium compound panels	Laminate panels
Carbide saw blade	X	X	X	X
Slitting unit X X
Adjustable groove cutter	X
Plasterboard milling cutter	X X
Aluminium compound milling cutter			X

10 Exploded drawing and spare parts list

The corresponding information in respect of spare parts can be found on our homepage: www.mafell.com

Sommaire

Incertitude K PA = 3 dB (A)

Äänenpainetaso L _PA = 96 dB (A)

Epävarmuus K _PA = 3 dB (A)

Äänitehotaso L_WA = 104 dB (A)

Epävarmuus K _WA = 3 dB (A)

- PVC, plexi, PA, alusandwich

- Taso: 1 - 6

5.8 Arbeta after mall

Negotovost K PA = 3 dB (A)

Raven zvočne moči L _WA = 104 dB (A)

Negotovost K_WA = 3 dB (A)

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