KSS 40 18M bl - Saw Mafell - Free user manual and instructions

USER MANUAL KSS 40 18M bl Mafell

Mechanical tool assembly with a cutting edge and mounting bracket (no visible text or symbols)

MAF02100/a

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

3D mechanical assembly diagram showing a cutting tool with labeled parts (1, 4), no readable text or symbols beyond labels

MAF02103/a

Mechanical component diagram showing a lever mechanism with labeled parts 1 and 2 (no text or symbols beyond labels)

MAF02104/a

Mechanical assembly diagram showing a lever mechanism mounted on a metal frame with a vertical guide rod (no text or symbols visible)

MAF02105/a

21 20 11 7

MAF02106/b

max. 5 max. 5 8

MAF00806/a

100% 75% 50% 25% =<20%

MAF02107/a

GB - EC Declaration of Conformity

We herewith confirm that the machine KSS40 18M bl 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	Rechargeable battery specifications	22
2.3	Machine identification	22
2.4	Technical data	23
2.5	Emissions	23
2.6	Scope of supply	24
2.7	Safety devices	24
2.8	Use according to intended purpose	24
2.9	Residual risks	24
3	Safety instructions	25
4	Setting / Adjustment	27
4.1	Charging the rechargeable battery	27
4.2	Fitting the rechargeable battery	27
4.3	Removing the rechargeable battery	28
4.4	Chip extraction	28
4.5	Saw blade selection	28
4.6	Saw blade change	28
4.7	Riving knife/splitter	28
5	Operation	28
5.1	Initial operation	29
5.2	Switching on and off	29
5.3	Cutting depth adjustment	29
5.4	Setting for bevel cuts	29
5.5	Setting for mitre cuts	29
5.6	Plunge cuts	29
5.7	Sawing with FLEXI rail	29
5.8	Sawing shadow gaps	30
5.9	Sawing with parallel stop	30
5.10	Sawing according to tracings with guide rail	30
5.11	Sawing according to tracings without guide rail	30
6	Service and maintenance	31
6.1	Storage	31
6.2	Transport	31
6.3	Disposal of rechargeable batteries/batteries	31
7	Troubleshooting	32
8	Special accessories	34
9	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

in respect of machines with item number 91D501, 91D502, 91D503, 91D521, 91D548

2.1 Manufacturer's data

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

2.2 Rechargeable battery specifications

The CE Declaration of Conformity with regard to the rechargeable batteries can be found on our website www.mafell.com in the footer area under the header Legal Matters, Declaration of Conformity.

2.3 Machine identification

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

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 electrical tools together with domestic waste!

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.

Read the operating instructions. This reduces the risk of injury.

Protect the rechargeable battery from heat, excessive solar radiation, fire, frost, water and humidity.

Protect rechargeable battery packs from humidity!

Protect rechargeable battery packs from fire!

There is danger of explosion!

CAS CORDLESS ALLIANCE SYSTEM

Cordless Alliance System (=CAS) is a cross-manufacturer battery pack system.

Further information is available at www.cordless-alliance-system.com

2.4 Technical data

Type of motor	brushless
Operating voltage	18 V DC
Speed during idling	6700 rpm
Cutting depth 0°/45°	42/29 mm (1 21/32, 1 9/64 in.)
Tilting saw unit	0 – 45°
Saw blade diameter max/min	122/112 mm (4 51/64, 4 13/32 in.)
Saw blade body thickness	1.2 mm (3/64 in.)
Tool cutting width	1.8 mm (0.070 in.)
Saw blade mounting hole	20 mm
Hose connector diameter	28 mm (1 7/64 in.)
Weight with rechargeable battery, without parallel stop	2.8 kg (6.2 lbs)
Dimensions incl. guide assembly (W x L x H)	200 x 580 x 200 mm (7 7/8 x 21 21/32 x 7 7/8 in.)
as cross-cutting system
Cutting depth 0°/45°	40/27 mm (1 9/16, 1 1/16 in.)
Cutting length at 12/40 mm workpiece thickness	337/292 mm (13 1⁄4, 11 1⁄2 in.)
Weight with rechargeable battery and guide assembly	3.6 kg (7.9 lbs)

2.5 Emissions

The declared noise emission values have been measured in accordance with EN 62841-1 and EN 62841-2-5 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!

2.5.1 Noise emission specifications

Noise emission values determined according to EN 62841-1 and EN 62841-2-5:

Sound pressure level	L_PA = 95 dB (A)
Uncertainty K	_PA = 3,0 dB (A)
Sound power level L	_PA = 103 dB (A)
Uncertainty	K_PA = 3,0 dB (A)

The noise measurement was recorded using the saw blade included in the standard equipment.

2.5.2 Vibration specifications

The typical hand-arm vibration is less than 2.5 m/s ^2 .

2.6 Scope of supply

Cross-cutting system KSS40 18 M bl complete with:

1 carbide-tipped circular saw blade ∅ 120 mm (4 ¾ in.), 24 teeth

1 riving knife/splitter (thickness 1.2 mm / 3/64 in.)

1 hose connector

1 parallel stop

1 service tool in bracket on the machine

1 carrying case Max

1 operating manual

1 folder "Safety Instructions"

2 clamping claws for Item No. 91D501, 91D521

1 FLEXI rail FX 140 for cutting length max. 140 cm (55 in.) for Item No. 91D501, 91D521

1 charger APS M for Item No. 91D501, 91D521

2 rechargeable batteries 18 M 99 LiHD for Item No. 91D501, 91D521

1 chip bags

2.7 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

- Riving knife / splitter

- Index mechanism and electrical brake

- Hose connector

2.8 Use according to intended purpose

The MAFELL cross-cutting system is exclusively suited for longitudinal and cross cutting of solid wood.

Panel materials such as chip board, core board and medium density fibre board can also be processed.

Use approved saw blades 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.

So as to use the machine as intended, comply with the operating, maintenance and repair instructions specified by Mafell.

Only use original Mafell / CAS rechargeable batteries and accessories.

Battery packs marked with CAS are 100% compatible with CAS devices (Cordless Alliance System).

2.9 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 saw blade in the vicinity of the starting aperture below the base plate.

- Touching the part of the saw blade that protrudes below the workpiece when cutting.

- Touching of turning parts from the side: saw blade, clamping flange and flange screw.

- Machine backlash if the blade gets stuck in the workpiece.

• Breakage of the saw blade and risk of the blade or pieces of the blade being hurled away.
• Accidental activation if rechargeable battery is not unplugged.
• Hearing can be impaired when working for long periods without ear protectors.
• Emission of harmful wood dusts during longer operation without extraction.
• Snapping open of the FLEXI rail if used improperly.

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 stipulated for the respective operating sequence and do not effect any modifications on the machine that could impair safety.
• Protect the machine and the rechargeable batteries from humidity!
• Do not throw the rechargeable batteries into a fire!
• Do not use any defective or deformed rechargeable batteries!
• Do not open the rechargeable batteries!
• Do not touch the contacts of the rechargeable batteries and do not short-circuit them!
• A slightly acidic, combustible liquid may leak from defective li-ion rechargeable batteries! If any battery liquid is leaking and comes in contact with the skin, immediately rinse with a copious amount of water. If any battery liquid gets into your eyes, rinse with clean water and immediately consult a doctor for medical treatment!

• Remove the rechargeable batteries from the machine before carrying out any setting, retooling, maintenance or cleaning tasks.

• Ensure that the machine is switched off when you push in the rechargeable battery.

• Please remove the rechargeable battery from the machine if the machine is put down, transported or stored unattended.

Do not use:

• Cracked and misshapen saw blades.
• Saw blades made of high speed steel (HSS saw blades).
• Blunt saw blades as they impose an excessive load on the motor.
• Saw blades with a base body with a thickness greater than, or a cutting width (setting) less than, the thickness of the riving knife / splitter.
• Saw blades which are not suitable for the saw blade's idling speed.
• Grinding discs

Instructions on the use of personal protective equipment:

• Always wear ear protectors during work.
• Always where a dust mark during work.
• Always wear protective goggles during work.

Instructions on operation:

Sawing method

Danger

• Keep hands away from cutting area and the blade. Keep your second hand on auxiliary handle, or motor housing. If both hands are holding the saw, they cannot be cut by the blade.
• Do not reach underneath the workpiece. The guard cannot protect you from the blade below the workpiece.
• Adjust the cutting depth to the thickness of the workpiece. Less than a full tooth of the blade teeth should be visible below the workpiece.

• Never hold the workpiece in your hands or across your leg while cutting. Secure the workpiece to a stable platform. It is important to support the work properly to minimise body exposure, blade binding, or loss of control.

• Hold the power tool by insulated gripping surfaces, when performing an operation where the cutting tool may contact hidden wiring or its own cord. Contact with a "live" wire will also make exposed metal parts of the power tool "live" and could give the operator an electric shock.

• When ripping, always use a rip fence or straight edge guide. This improves the accuracy of cut and reduces the chance of blade binding.
• Always use blades with correct size and shape (diamond versus round) of arbour holes. Blades that do not match the mounting hardware of the saw will run off-centre, causing loss of control.
• Never use damaged or incorrect blade washers or bolt. The blade washers and bolt were specially designed for your saw, for optimum performance and safety of operation.

Kickback causes and related warnings

• kickback is a sudden reaction to a pinched, jammed or misaligned saw blade, causing an uncontrolled saw to lift up and out of the workpiece toward the operator;
• When the blade is pinched or jammed tightly by the kerf closing down, the blade stalls and the motor reaction drives the unit rapidly back toward the operator;
• if the blade becomes twisted or misaligned in the cut, the teeth at the back edge of the blade can dig into the top surface of the wood causing the blade to climb out of the kerf and jump back toward the operator.

Kickback is the result of saw misuse and/or incorrect operating procedures or conditions and can be avoided by taking proper precautions as given below.

• Maintain a firm grip with both hands on the saw and position your arms to resist kickback forces. Position your body to either side of the blade, but not in line with the blade. Kickback could cause the saw to jump backwards, but kickback forces can be controlled by the operator, if proper precautions are taken.
• When blade is binding, or when interrupting a cut for any reason, release the trigger and hold the saw motionless in the material until the blade comes to a complete stop. Never attempt to remove the saw from the work or pull the saw

backward while the blade is in motion or kickback may occur. Investigate and take corrective actions to eliminate the cause of blade binding.

• When restarting a saw in the workpiece, centre the saw blade in the kerf so that the saw teeth are not engaged into the material. If a saw blade binds, it may walk up or kickback from the workpiece as the saw is restarted.
• Support large panels to minimise the risk of blade pinching and kickback. Large panels tend to sag under their own weight. Supports must be placed under the panel on both sides, near the line of cut and near the edge of the panel.
• Do not use dull or damaged blades. Unsharpened or improperly set blades produce narrow kerf causing excessive friction, blade binding and kickback.
• Blade depth and bevel adjusting locking levers must be tight and secure before making the cut. If blade adjustment shifts while cutting, it may cause binding and kickback.
• Use extra caution when sawing into existing walls or other blind areas. The protruding blade may cut objects that can cause kickback.

Lower guard function

• Check the lower guard for proper closing before each use. Do not operate the saw if the lower guard does not move freely and close instantly. Never clamp or tie the lower guard into the open position. If the saw is accidentally dropped, the lower guard may be bent. Raise the lower guard with the retracting handle and make sure it moves freely and does not touch the blade or any other part, in all angles and depths of cut.
• Check the operation of the lower guard spring. If the guard and the spring are not operating properly, they must be serviced before use. Lower guard may operate sluggishly due to damaged parts, gummy deposits, or a build-up of debris.
• The lower guard may be retracted manually only for special cuts such as "plunge cuts" and "compound cuts". Raise the lower guard by the retracting handle and as soon as the blade enters the material, the lower guard must be

released. For all other sawing, the lower guard should operate automatically.

- Always observe that the lower guard is covering the blade before placing the saw down on bench or floor. An unprotected, coasting blade will cause the saw to walk backwards, cutting whatever is in its path. Be aware of the time it takes for the blade to stop after switch is released.

Riving knife function

• Use the appropriate saw blade for the riving knife. For the riving knife to function, the body of the blade must be thinner than the riving knife and the cutting width of the blade must be wider than the thickness of the riving knife.
• Adjust the riving knife as described in this instruction manual. Incorrect spacing, positioning and alignment can make the riving knife ineffective in preventing kickback.
• Always use the riving knife except when plunge cutting. The riving knife must be replaced after plunge cutting. The riving knife causes interference during plunge cutting and can create kickback.
• For the riving knife to work, it must be engaged in the workpiece. The riving knife is ineffective in preventing kickback during short cuts.
• Do not operate the saw if the riving knife is bent Even a light interference can slow the closing rate of a guard.

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 Charging the rechargeable battery

Check whether the rated voltage of the rechargeable battery agrees with the information specified on the machine.

Rechargeable battery and charger are matched to each other. Only use the MAFELL – APS 18 chargers for recharging.

Before using a new machine, first of all charge the rechargeable battery.

A description of how to start up and charge the APS 18 can be found in the appended instructions "APS 18 rechargeable power station".

The rechargeable battery is equipped with a temperature monitoring system. This guarantees that the rechargeable battery is only charged in the temperature range between 0°C and 50°C. This achieves a long service life for the rechargeable battery.

A considerably shortened operating time per charging procedure indicates that the rechargeable battery is spent and needs to be replaced.

Danger

Explosion hazard

Protect the rechargeable battery from heat, fire and moisture.

Do not place the rechargeable battery onto heating appliances and do not expose the rechargeable battery to strong solar radiation for a longer period of time. Temperatures above 50^ C are detrimental to the rechargeable battery. Allow a heated rechargeable battery to cool down before charging it.

The optimum storage temperature ranges between 10^ C and 30^ C.

Do not open the rechargeable battery and protect it from impacts. Keep the rechargeable battery in a dry and frost-proof place.

Danger

Cover the rechargeable battery's contacts if it is stored outside the charger. There is a fire and explosion hazard in case of a short circuit caused by metallic bridging.

Follow the instructions for the protection of the environment.

4.2 Fitting the rechargeable battery

Slide the charged rechargeable battery into the battery guide behind the handle until it perceptibly engages.

Before using the machine, convince yourself that the rechargeable battery is firmly seated in the machine.

4.3 Removing the rechargeable battery

Unlock the rechargeable battery by pressing the locking lever 1 (Fig. 3) and pull it out of the battery guide.

Do not use force to do so.

4.4 Chip extraction

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 3 (Fig. 3) is 28 mm (1 7/64 in.).

4.5 Saw blade selection

Use a sharp tool to obtain a good cut quality and select a tool from the following list according to material and application:

For cuts along and across the grain in soft or hard wood:

- Circular saw blade carbide ∅ 120 x 1.8 x 20 mm (4 34 x 5/64 in. x 20 mm), 24 teeth

For cuts especially along the grain in soft or hard wood:

- Circular saw blade carbide ∅ 120 x 1.8 x 20 mm (4 ¾ x 5/64 in. x 20 mm), 12 teeth

For cuts especially across the grain in soft or hard wood:

- Circular saw blade carbide ∅ 120 x 1.8 x 20 mm (4 ¾ x 5/64 in. x 20 mm), 40 teeth

For cuts in laminate:

- Circular saw blade carbide ∅ 120 x 1.8 x 20 mm (4 ¾ x 5/64 in. x 20 mm), 40 trapezoidal teeth

Order No. see special accessories.

4.6 Saw blade change

Danger

Unplug the rechargeable battery for all service work.

• Press the locking bolt 8 (Fig. 2).
• Using the Allen-key 3 (brackets Fig. 1), unfasten the flange screw 8 (Fig. 3) counter clockwise; remove the screw as well as the front clamping flange 7.
• Now you can remove the saw blade after opening the retractable saw guard 9.
• The clamping flanges must be free of adhering parts.
• Pay attention to the sense of rotation when inserting the saw blade.
  • Afterwards, mount the clamping flange, attach the flange screw and tighten it by clockwise turning.
  • In doing so, keep the locking bolt depressed.

4.7 Riving knife/splitter

Danger

Unplug the rechargeable battery for all service work.

The riving knife / splitter 6 (Fig. 3) prevents the saw blade from jamming during longitudinal cutting. The correct distance to the saw blade is shown in (Fig. 8).

• For adjustment, unfasten the screw 4 (Fig. 3) with the Allen-key supplied with the saw 3 (Fig. 1).
• Adjust the riving knife/splitter by shifting it in its longitudinal slit. Afterwards retighten the screw.

5 Operation

During operation and given corresponding conditions - in particular if the air is dry, or if materials such as coated board materials are used and there is no anti-static suction hose - electrostatic discharges via the operator can occur. The electronic system's protective function is activated and the machine goes into a safe state. The machine switches off automatically.

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 press the switch-on lock 1 (Fig. 1) and then press the switch trigger 2.
• Switching off: To switch off, release the switch trigger.

5.3 Cutting depth adjustment

The cutting depth is continuously variable between 0 and 40 mm (1 15/16 in.).

Proceed as follows:

• Unfasten the clamping lever 5 (Fig. 1).
• Set the cutting depth with the plunge lever 6 (Fig. 2).
• The cutting depth can be read off the scale 2 (Fig. 5) on the cover. Zone 1 on the plunge lever with the red background serves as indicator for this purpose.
• Retighten the clamping lever.

Always set the cutting depth approx. 2 to 5 mm (5/64 to 13/64 in.) larger than the material thickness to be cut.

5.4 Setting for bevel cuts

For bevel cuts, the saw unit can be set to any angle between 0^ and 45^ .

• Unfasten the wing screws 5 (Fig. 3).
• Adjust the angle according to the scale on the segment for tilting.
  • Afterwards, tighten the wing screws 5.

5.5 Setting for mitre cuts

• Release the limit stop 21 (Fig. 7) and adjust the angle according to the scale on the guide rail.
  • Afterwards retighten the limit stop.
• Place the machine with the two stop bolts at the bottom side of the guide rail against the workpiece to be processed and carry out the cut by pushing the machine forward.
• when the cut is completed, switch off the saw by releasing the switch trigger 2 (Fig. 1).

- Pull back the machine into home position keeping it applied to the workpiece and take it off the workpiece in this position. With doing so, you guarantee that the retractable saw guard is completely closed.

5.6 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. Keep a firm hold on the machine handle during plunging and push the saw lightly forward!

• Unfasten the clamping lever 5 (Fig. 1) on the switched off machine.
• Reset the plunge lever 6 (Fig. 2).
• Open the retractable saw guard with the lever 2 (Fig. 3) so that the machine can be placed onto the workpiece to be machined. The saw blade is now running freely above the material and can be aligned for tracing.
• Switch on the machine only now.
• Push the plunge lever 6 (Fig. 2) vertically downwards so that the saw blade plunges vertically into the workpiece. While doing so, the plunge depth can be read off the scale 2 (Fig. 5). The riving knife/splitter swings up and away when the blade enters the workpiece. As soon as the slit behind the saw blade is cleared during the forward motion of the machine, the riving knife reverts to its normal position.

5.7 Sawing with FLEXI rail

Danger

The support rail is pretensioned and may snap open in an uncontrolled manner - risk of injury. It should therefore be securely held with both hands during opening and closing.

Initial operation

Trim the splinter guard 4 (Fig. 4) before initial operation:

• Place the FLEXI rail on a flat support.
• Set the cutting depth to approx. 3 mm (1/8 in.) and the angle scale to 0°.
• Turn on the machine and push it evenly in the direction of the cut.

The resulting cut edge on the splinter guard serves as tracing edge for straight cuts and bevel cuts.

- Place the FLEXI rail onto the workpiece. Knock against the workpiece and align it on the tracing.

So as to fix the FLEXI rail, tighten the two clamping claws 1 (Fig. 6) with the screw clamps.

Operating method

• Set the cutting depth and cutting angle on the machine.
• Place the machine on the start of the FLEXI rail such that the guide elements 1 (Figure. 4) of the rail engage in the base plate groove.
• Turn on the machine and push it evenly in the direction of the cut.

Do not clean the FLEXI rail with solvents. Non-skid coating may get damaged.

5.8 Sawing shadow gaps

The minimum shadow gap width is:

• if used without parallel stop 13 mm (33/64 in.)
• if used with parallel stop 14 mm (35/64 in.) (at cutting depth of 0 - 32 mm / 0 - 1 ¼ in.)
• if used with parallel stop 18 mm (45/64 in.) (at cutting depth of 32 - 42 mm / 1 ¼ - 1 21/32 in.)
• Set the required cutting depth.
• Retract the retractable saw guard with the lever 2 (Fig. 3) and set the machine onto the first fitted workpiece.
• Switch on the machine and push the machine evenly in cutting direction, in addition using the extraction device.

5.9 Sawing with parallel stop

The parallel stop 4 (Fig. 1) serves to cut 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. 65 mm (2 9/16 in.) and on the left-hand side to approx. 250 mm (9 27/32 in.).

- You can adjust the cutting width after unfastening the wing screws 9 (Fig. 2) by moving the limit stop accordingly and afterwards refastening the wing screws.

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

5.10 Sawing according to tracings with guide rail

When sawing according to tracing, the right edge of the guide rail serves as tracing indicator. This also applies to bevel cuts. Please take note of Section 5.4.

• For sawing, place the guide rail onto the workpiece.
• Switch on the machine (see Chapter 5.2) and slide the machine evenly in cutting direction.
• When the cut is completed, switch off the saw by releasing the switch trigger 2 (Fig. 1)
• 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.

5.11 Sawing according to tracings without guide rail

Danger

When sawing without guide rail it is imperative to install the enclosed parallel stop. It serves as double support to improve machine guidance and is for your safety.

Set the machine's cutting depth to at least 30 mm (13/16 in.). Afterwards, you can remove the machine from the guide rail to the rear by actuating the locking lever 20 (Fig. 7).

The base plate is equipped with a tracing edge 10 (Fig. 3) both for straight cuts and for bevel cuts. This tracing edge corresponds to the saw blade's inside. For bevel cuts, the tracing can be viewed through the opening on the left-hand side of the upper saw guard.

• Hold the machine by its handles and place the front part of its base plate onto the workpiece.
• Switch on the machine and evenly advance the machine in cutting direction.
• When the cut is completed, switch off the saw by releasing the switch trigger 2 (Fig. 1).

6 Service and maintenance

Danger

Unplug the rechargeable battery for 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.

6.2 Transport

The included Li-ion rechargeable batteries are subject to the requirements of dangerous goods legislation. The rechargeable batteries can be transported by the user on the road without any further requirements.

For the dispatch by third parties (e.g.: air transport or forwarding agent), special requirements for packaging and labelling must be observed. In this case, a dangerous goods expert must be consulted when preparing the package.

Only dispatch rechargeable batteries if their housing is undamaged. Tape open contacts and pack the rechargeable battery so that it does not move in the packaging.

Please also observe any further national regulations.

6.3 Disposal of rechargeable batteries/batteries

Electrical tools, rechargeable batteries, accessories and packaging should be recycled in an environmentally friendly manner.

Do not dispose of electrical tools together with domestic waste!

For EU countries only:

According to the European Directive 2002/96/EC, power tools that are no longer serviceable, and according to the European Directive 2006/66/EC, defective or used rechargeable batteries/batteries must be collected separately and recycled in an environmentally sound manner.

Return unusable rechargeable batteries/batteries directly to:

Germany

Stiftung

GRS Batterien

Heidenkampsweg 44

20097 Hamburg

Germany

Rechargeable batteries/batteries:

Li-lon:

Please comply with the information in Section "Transport", page 17.

Subject to changes.

7 Troubleshooting

Danger

Determining the causes for existing defects and eliminating these always requires increased attention and caution. Unplug the rechargeable battery 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	Remedy
Machine cannot be switched on.	Discharge the rechargeable battery	Charge the rechargeable battery
	Rechargeable battery not engaged in end position	Allow rechargeable battery to engage completely
Rechargeable battery almost empty, an LED on the rechargeable battery is flashing.	Electronic system protects the rechargeable battery from deep discharge.	Check, press button 11. Fig. 1 + 7 + 9Only one LED is still glowing.Charge the rechargeable battery.
Overload, machine switches off. A	sustained load has overheated the machine or the rechargeable battery. A warning signal is sounded (constant bleeping).It will go out after max. 30 seconds or after the switch trigger is released.	Allow the machine and the rechargeable battery to cool down.The rechargeable battery can be cooled down much faster with a charger with air cooling.The machine can also be cooled down much faster by using a different rechargeable battery and idling the machine.
The machine switches off at a sudden increase in load.	The sudden increase in load also causes the current that is required for the machine to rise. This rise in current, which occurs when there is a sudden blockage or backlash, is measured and then leads to the machine being switched off.	Switch off the machine by releasing the switch trigger.Afterwards, you can switch the machine back on again and resume work as normal.Try to avoid further blockages.
The machine switches off during operation.	Electrostatic charge. The electronic system's protective function is activated and the machine goes into a safe state. The machine switches off.	Use an anti-static suction hose
Defect Cause Remedy
Saw blade jams when the machine is advanced.	Feed rate too fast Reduce feed speed
	Blunt saw blade	Release the switch immediately. Remove the machine from the workpiece and replace the saw blade
	Tension in the workpiece Widen the kerf with a wedge
	Poor machine guidance	Use parallel stop
	Uneven workpiece surface	Straighten the surface
Burn marks on the cut surfaces The saw blade used is unsuitable for the task or blunt		Replace saw blade
Chip ejection blocked	Wood is too damp	Clean chip ejection Use dry wood
	Extended operation without extraction	Connect to an external extraction, e.g. portable dust extractor
Saw blade vibrates in the work piece	Saw blade not correctly adjusted	Retighten saw blade
	Work piece not fastened Fasten work piece with clamps
Saw blade stops - motor continues to turn	Saw blade not correctly fastened	Retighten saw blade
Lower mobile protective cover does not close or closes only slowly	Chips and pieces of wood in the bottom mobile protective cover	Remove chips and pieces of wood

8 Special accessories

• Saw blade carbide ∅ 120 x 1.8 x 20 mm (4 ¾ x 5/64 in. x 20 mm), 12 teeth, Order No. 092560 WZ (longitudinal cut)
• Saw blade carbide ∅ 120 x 1.8 x 20 mm (4 ¾ x 5/64 in. x 20 mm), 24 teeth, Order No. 092558 WZ (longitudinal and cross cuts)
• Saw blade carbide ∅ 120 x 1.8 x 20 mm (4 ¾ x 5/64 in. x 20 mm), 40 teeth, Order No. 092559 FZ/TR (cross cut)
• Saw blade carbide ∅ 120 x 1.8 x 20 mm (4 ¾ x 5/64 in. x 20 mm), 40 teeth, Order No. 092578 TR (laminate)
• FLEXI rail FX 140, cpl. Order No. 204372
• Accessories for FLEXI rail:
• Screw clamp Order No. 093281
• Rechargeable battery PowerTank 18 M 144 LiHD Order No. 094498
• Rechargeable battery PowerTank 18 M 99 LiHD Order No. 094503
• Power set 2: 2x 18 M 99 LiHD + APS M Order No. 209599
• Power set 3: 2x 18 M 144 LiHD + APS M+ Order No. 209598
• Rechargeable power station APS M GB Order No. 094493
• Rechargeable power station APS M Order No. 094492
• Guiding device S packed Order No. 208169
• Chip bag complete Order No. 206787

9 Exploded drawing and spare parts list

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

Français

Sommaire

$$ K _ {P A} = 3, 0 \mathrm{dB(A)} $$

Äänitehotaso L

$$ _ {W A} = 1 0 3 \mathrm{dB(A)} $$

Epävarmuus K

$$ _ {W A} = 3, 0 \mathrm{dB(A)} $$

$$ K _ {P A} = 3, 0 \mathrm{dB(A)} $$

Lydeffektniveau L

$$ _ {W A} = 1 0 3 \mathrm{dB(A)} $$

Usikkerhed K

$$ _ {W A} = 3, 0 \mathrm{dB(A)} $$

Negotovost K_PA = 3,0 dB (A)

Raven zvočne moči L PA = 103 dB (A)

Negotovost K _PA = 3,0 dB (A)

Neistota K _WA = 3,0 dB (A)

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