LS 103 Ec - Milling machine Mafell - Free user manual and instructions

Product type	Chain mortiser (chain slot mortiser)
Brand	Mafell
Model	LS 103 Ec
Service voltage	230 V AC / 120 V AC
Mains frequency	50 Hz / 60 Hz
Continuous power consumption	2500 W
Continuous current consumption	13 A (230 V) / 20 A (120 V)
No-load speed	4050 min⁻¹ (230 V) / 4400 min⁻¹ (120 V)
Mortising depth	100 mm (without FG 150 support); 150 mm (with FG 150 support)
Weight (machine only)	8.7 kg
Weight of guide support FG 150	4.6 kg
Sound pressure level	100 dB(A)
Sound power level	108 dB(A)
Hand-arm vibration	5.1 m/s²
Protection class	II
Standard equipment	Guide rail, mortising chain, sprocket, transverse stop, mortising tools, instruction manual
Intended use	Mortising of solid wood with mortising chains
Safety instructions	Wear hearing protection, mask and goggles; disconnect before maintenance; do not work without chain guard
Chain maintenance	Clean and lubricate every 2 hours of work in a thin oil bath
Lubrication	Use special MAFELL grease part no. 049040
Storage	Clean thoroughly and spray metal parts with a rust inhibitor
Available accessories	Guide support FG 150, notching devices SG 230/400/500, guides and replacement chains

Frequently Asked Questions - LS 103 Ec Mafell

How to change the mortising chain?

Disconnect the mains plug. Release the chain with the threaded pin (14), remove the chain guide (11), unscrew the socket-head screw (16) and the countersunk screw in the drive shaft, then remove the sprocket, chain and guide rule assembly. Mount the new chain respecting the direction of the teeth and tension it until it can be lifted about 6 mm at the center of the guide rail.

What is the maximum mortising depth?

The standard mortising depth is 100 mm. With the FG 150 guide support (ref. 200980), it can reach 150 mm.

How to adjust the transverse stop?

Loosen the locking lever (8) and adjust the distance on the graduated scale (7) between 8 and 150 mm. Observe the reading edge according to the slot width (30, 35 or 40 mm). Then retighten the lever.

How to adjust the mortising depth?

Loosen the clamping lever (10) and set the depth stop (9) to the desired value using a rule. Then tighten the lever. Note: do not set it in the direction of mortising. The depth depends on the chain set used.

What accessories are available for the LS 103 Ec?

Accessories include the FG 150 guide support (ref. 200980), notching devices SG 230, SG 400, SG 500, guides of various dimensions (28x40x100, etc.), mortising chains (28x35/40/50x100, etc.) and replacement sprockets.

How to maintain the mortising chain?

Every 2 hours of operation, clean the chain and lubricate it in a thin oil bath. To do this, remove the chain (see chapter 4.3). A blunt chain must be replaced or sharpened by an authorized MAFELL service.

What are the essential safety instructions?

Always wear ear protection, a dust mask and safety goggles. Disconnect the plug before any tool change or maintenance. Never work without the chain guard. Ensure the transverse stop is fixed and in contact with the workpiece.

What to do if the machine stops during cutting?

Check the mains fuses for a power failure. If the machine is overloaded, reduce the feed speed. Worn carbon brushes require intervention by a MAFELL after-sales service.

How to store the machine if not used for a long time?

Clean the machine thoroughly and spray bare metal parts with a rust inhibitor. Store it in a dry, dust-free place.

What are the residual risks when using?

Risks of contact with the mortising chain (open part, side, under the chain), kickback of the machine if the stop is not fixed, chain breakage, hearing damage without protection, and inhalation of wood dust without extraction.

USER MANUAL LS 103 Ec Mafell

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

GB - EC Declaration of Conformity

We herewith confirm that the machine LS 103 Ec 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

924220, 924221, 924228, 924229, 924240, 924260,

924262, 924263

Mafell AG

Beffendorfer Str. 4

1 Signs and symbols 15
2 Product information 15
2.1 Manufacturer's data 15
2.2 Machine identification 15
2.3 Technical data 16
2.4 Emissions 16
2.5 Scope of supply 16
2.6 Use according to intended purpose 17
2.7 Residual risks 17
3 Safety instructions 17
4 Setting/Adjustment 18
4.1 Mains connection 18
4.2 Installation mortising chain set 18
4.3 Mortising chain change 18
4.4 Chain wheel change 19
5 Operation 19
5.1 Initial operation 19
5.2 Switching on and off 19
5.3 Cross fence setting 19
5.4 Mortising depth adjustment 20
5.5 Operating method 20
5.6 Mortising recesses 20
6 Service and maintenance 20
6.1 Mortising chains 20
6.2 Storage 20
7 Troubleshooting 20
8 Optional accessories 21
9 Exploded drawing and spare parts list 21

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 product no. 924201, 924202, 924203, 924204, 924205, 924206, 924220, 924221, 924228, 924260, 924262, 924263

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	120 V AC
Mains frequency	50 Hz	60 Hz
Input power continuous operation	2500 W
Power consumption continuous operation	13 A	20 A
Speed during idling	4050 rpm	4400 rpm
Mortising depth	100 mm (3 15/16 in.)
Mortising depth with guide support stand FG 150, order No. 200	150 mm (5 7/8 in.)
980
Weight without mains cable LS 103 Ec	8.7 kg (19.18 lbs)
Weight guide support stand FG 150, order No. 200 980	4.6 kg (10.1 lbs)

2.4 Emissions

The declared noise emission values have been measured in accordance with 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 ist 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 = 100dB(A)

Uncertainty K PA = 1,5dB (A)

Sound power level L WA=108 dB (A)

Uncertainty K_WA = 1,5dB(A)

2.4.2 Vibration specifications

The typical hand-arm vibration is 5.1m / s^2

2.5 Scope of supply

Single-phase chain mortiser LS 103 Ec complete with:

1 guide rail, cpl.
1 mortising chain
1 chain wheel
1 crossfeed stop
2 operating tools
1 operating manual
1 folder "Safety Instructions"

2.6 Use according to intended purpose

The single-phase chain mortiser is exclusively intended for mortising solid wood using mortising chains. The dimensions of the mortising chain sets used (guide rail, mortising chain and chain wheel) must correspond to the mortising chain sets listed in the operating instructions.

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.

2.7 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 mortising chain in the exposed area.
• Touching the part of the mortising chain that protrudes below the workpiece when mortising.
• Touching the mortising chain from the side.
• Tearing of the mortising chain.
• Backlash of the machine against the operator if the cross fence is not fastened during freehand milling.
• 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 harmful wood dusts during longer operation without extraction.

3 Safety instructions

Danger

Always observe the following safety instructions and the safety regulations applicable in the respective country of use! Please also read the safety information in the enclosed folder 070500 "Safety instructions" (according to standard 62841-1).

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.

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:

• Provide for an unobstructed and slip-proof location with sufficient lighting.
• The power plug must be pulled before replacing tools, making adjustments and repairing malfunctions (this also comprises removing jammed splinters).

• Do not work on workpieces which are too small or too large for the capability of the machine.

• Clamp the mortising chain and the guide rail properly and keep it in good repair. Before reusing them, repair defective mortising chains professionally and only use sharp mortising chains!

• Caution: For machines without guide support stand FG 150, use solely 100mm (3 5/16 inch) mortising chain sets!
• Remove the chain guard only for a tool change and screw it back on again immediately afterwards. Never work without chain guard!
• Never transport the chain mortiser with running mortising chain and avoid touching the ground with the running mortising chain!
• The switch may not be wedged.
• Before switching on the mortising chain, check whether it is properly tensioned.
• Whenever possible secure the workpiece from pivoting or sliding away, overturning and luffing up, e.g by means of clamps.
• Only begin mortising the workpiece when the mortising chain has achieved its full speed.
• Examine the workpiece for foreign objects. Never attempt to stem into metal objects, such as nails.
• Keep a firm hold on the machine already before switching it on. The mortising chain must stand unobstructed while doing so. Apply the machine for the mortising operation with running mortising chain. Pay attention to a secure footing.
• Always lead the connecting cable away from the machine to the rear while mortising.
• Match the feed speed during mortising to the material thickness. Mortising too quickly leads to motor overload, to unclean mortises and to the mortising chain blunting quickly.
• Only remove the machine from the workpiece if it has come to a standstill.
• Do not reach into the chip ejector and the unprotected area of the mortising chain while the machine is running.
• Before switching on the machine for freehand milling, pay attention that the cross fence is fastened and rests against the workpiece. Milling must not start without cross fence!
• Only use the machine outdoors or in well ventilated rooms.
• Wear a dust mask during machine operation.

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.
• Wear protective gloves for all maintenance and repair work.

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 Installation mortising chain set

Danger

Pull the power plug during all service work.

• Lightly screw on the guide rail with the cylinder head bolt. Pay attention that the guide rail rests planely in the guide on the gearbox case and possibly unscrew the threaded pin 14 (Fig. 1).
• The installation of mortising chain and chain wheel is carried out as described under 4.3 and 4.4.

4.3 Mortising chain change

Danger!

Pull the power plug during all service work.

Pay attention that the mortising chain to be clamped has been well sharpened as this is the basic requirement for correct mortising.

Proceed as follows to replace the mortising chain:

• First slacken the mortising chain by means of the threaded pin 14 (Fig. 1).
• Remove the chain guard 11 (Fig. 2) by simultaneously unfastening the two knurled screws.
• Unfasten the cylinder head bolt 16.

• Unfasten and remove the countersunk bolt in the transmission shaft.

• Remove the chain wheel, mortising chain and guide rail together.

• For installation, proceed in reverse order.
• Refit the new mortising chain together with the chain wheel and the guide rail and pay attention that the cutting teeth are running in working direction (see arrow on the chain guard 11 (Fig. 2)).
• Fasten the countersunk bolt in the transmission shaft.
• Lightly tighten the cylinder head bolt 16 and clamp the mortising chain with the threaded pin 14 (Fig. 1). The correct chain tension has been achieved if the mortising chain can be lifted approx. 6mm (1/4 in.) in the middle of the guide rail.
• Securely retighten the cylinder head bolt 16 (Fig. 2) after completion of the adjustment work.
• Refit the chain guard 11!

4.4 Chain wheel change

Danger

Pull the power plug during all service work.

• During a chain wheel change, the countersunk screw in the gear shaft must be unscrewed with the Allen key fastened on the machine by knocking lightly against the key.
• For installation, proceed in reverse order. Push the new chain wheel onto the gear shaft such that the chain wheel groove gears into the straight pin, which is pushed crossways through the gear shaft.

5 Operation

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

Danger

Pay attention that the mortising chain can be moved freely.

Lead the connecting cable away to the rear.

Hold onto the machine with both hands.

Only switch on the machine if the mortising chain has no contact with the workpiece.

• Switching on: First unlock the switch-on lock to the front by pressing the locking lever 4 (Fig. 2). Then actuate the control lever 3. As this is a switch without locking device, the machine will only run for as long as this switch is pressed.
• Switching off: Release control lever 3. The switch-on lock automatically takes effect again and secures the machine against accidental switch-on.

Switch-on procedures create a temporary reduction in voltage. In case of unfavourable grid conditions, this may lead to the impairment of other devices.

In case of grid impedances smaller than 0.27 Ohm, no interferences are to be expected.

5.3 Cross fence setting

The distance between mortise and collar side is stepplessly variable from 8 to 150mm (5/16 to 5 7/8 in.) with the crossfeed stop 6 (Fig. 2).

• Release the clamping lever 8 and set the distance on scale 7. Note the reading edge depending on the hole width 30, 35 or 40mm (1 3/16, 1 3/8 or 1 9/16 in.)!
• Securely retighten the clamping lever 8 afterwards. The clamping lever is adjustable and can be brought into any desired clamping position by lifting it.

5.4 Mortising depth adjustment

The mortise depth is continuously variable.

• Release clamping lever 10 (Fig. 2) and set the depth stop 9 to depth using a yard stick.
• Tighten clamping lever 10 (adjustable as 8) - do not place in mortising direction! The mortising depth depends on the mortising chain set used.

5.5 Operating method

To start mortising, hold the machine by its two handles 1 and 2 (Fig. 2) and guide it - the crossfeed stop 6 must rest against the wood. First mortise the start and end of the mortise and then the rest. Mortise with even pressure and infeed. The mortising chain should be cleaned and lubricated in a low viscosity oil bath after two hours of operation.

5.6 Mortising recesses

For this, two wooden ledges can be screwed on at the drill holes 4.5mm (11/64 in.) on the crossfeed stop 6 (Fig.2) (see Fig.4).

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 Mortising chains

The mortising chain used on the machine should be cleaned and lubricated in a low viscosity oil bath after two hours of operation. To do so, dismantle the mortising chain (see chapter 4.3).

Replace the blunt mortising chains or have them reground at a MAFELL customer service station or by a suitable sharpening service.

6.2 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, please contact your dealer or the MAFELL customer service directly.

Defect	Cause	Elimination
Machine cannot be switched on	No mains voltage	Check power supply
	Carbon brushes worn	Take the machine to a MAFELL customer service shop
Chip ejection blocked	Wood is too damp	Clean chip ejection
Machine stops while cutting is in process	Mains failure	Check mains back-up fuses
	Machine overloaded Reduce feed speed
	Carbon brushes worn	Take the machine to a MAFELL customer service shop

8 Optional accessories

• Guide support stand FG 150 Order No. 200980
• Slot mortising device SG 230 Order No. 200990
• Slot mortising device SG 400 Order No. 201000
• Slot mortising device SG 500 Order No. 201005
• Clamping device (for SG 400) Order No. 039602
• Guide rail, cpl. 28x40x100 Order No. 091010
• Guide rail, cpl. 28x40x150 Order No. 091011
• Guide rail, cpl. 28x30/35x100 Order No. 091012
• Guide rail, cpl. 28x30/35x150 Order No. 091013
• Guide rail, cpl. 30x30/35x100 Order No. 091014
• Guide rail, cpl. 28x1.5x150 Order No. 091016
• Guide rail, cpl. 28x2x150 Order No. 091017
• Mortising chain 28x35/40/50x100 Order No. 091224
• Mortising chain 28x35/40x100 Order No. 091230
• Mortising chain 28x35/40x150 Order No. 091234
• Spare links with rivets 28 mm Order No. 091279
  -Chain wheel 28x35/40 Order No.091683

9 Exploded drawing and spare parts list

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

Notes for after-sales service:

If a LS 103 Ec (with Cuprex motor) is to be mounted on an existing slot mortising device SG 400 or SG 500 at the customer's (up to year of manufacture 2006), the pinion cpl. (pos. 2), item No 200842 on the slot mortising device must be replaced by pinion cpl. 204740.

The handle on the pinion cpl. 204740 can be detached by means of the Allen key SW 4 which is included as accessory with the LS 103 Ec and used to attach the LS 103 Ec on the SG 400 / SG 500.

Sommaire

pour les machines portant le n d'art. 924201, 924202, 924203, 924204, 924205, 924206, 924220, 924221, 924228, 924260, 924262, 924263

bij machines met art.-nr. 924201, 924202, 924203, 924204, 924205, 924206, 924220, 924221, 924228, 924260, 924262, 924263

Koneille, joilla on tuote-nro: 924201, 924202, 924203, 924204, 924205, 924206, 924220, 924221, 924228, 924260, 924262, 924263

for maskiner med articelnummer 924201, 924202, 924203, 924204, 924205, 924206, 924220, 924221, 924228, 924260, 924262, 924263

K Maunam capT. No 924201, 924202, 924203, 924204, 924205, 924206, 924220, 924221, 924228, 924260, 924262, 924263

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MAFELL AG, Beffendorfer Straße 4, D-78727 Oberndorf / Neckar, Teilepoh +49 (0)7423/812-0, øakc +49 (0)7423/812-218, øl. nouTa [e-mail]

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IooTOMy Bcerda nCnoJb3yIte cpeIcTBa 3aunIbI opraHOB clyxa, daXe KOrda 3neKtpoHHCTpyMeHT pa6OtaET 6e3 harpy3kn!

2.4.1 DaaHbIe no n3JyueHnO wyma

3haenraaHyaMa, nmepeHHbIe, cornacho EN 62841, coctabnT:

ypoBHeH 3BykoBOrO daBneHnRA L PA=100dA(B(A)

norpewnoctbK PA=1,5D5(A)

ypoBHeHb 3ByKOBoM OuHocTn LwA = 108 d5 (A)

norpeuhoctb KwA=1,5D(A)

do maszyn z nr art. 924201, 924202, 924203, 924204, 924205, 924206, 924220, 924221, 924228, 924260, 924262, 924263

2.1 Dane dot.producenta

MAFELL AG, Beffendorfer Straße 4, D-78727 Oberndorf / Neckar, Telefon [phone], Faks +49 (0)7423/812-218, e-mail [e-mail]

6.1 Dluta Iancuszkowe

pro stroje s cislem položky 924201, 924202, 924203, 924204, 924205, 924206, 924220, 924221, 924228, 924260, 924262, 924263

2.1 Udaje k vyrobci

MAFELL AG, Beffendorfer Straße 4, D-78727 Oberndorf / Neckar, Telefon [phone], Fax [phone], E-Mail [e-mail]

2.2 Charakteristika stroje

za stroje s st. art. 924201, 924202, 924203, 924204, 924205, 924206, 924220, 924221, 924228, 924260, 924262, 924263

Negotovost K_PA = 1,5 dB (A)

Raven zvočne moči L WA = 108 dB (A)

Negotovost K WA=1,5dB(A)

2.4.2 Podatki o vibracijah

Tipčni tresljaj roke znaša 5,1 m/s².

2.5 Dobavni obseg

Fluksni verižni prebijalnik LS 103 Ec kompleten,vsebuje:

k strojom s vyr.č. 924201, 924202, 924203, 924204, 924205, 924206, 924220, 924221, 924228, 924260, 924262, 924263

2.1 Udaje o vyrobcovi

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