KSS 60 cc - Saw Mafell - Free user manual and instructions

USER MANUAL KSS 60 cc Mafell

Portable circular saw / cross-cutting system Translation of the original operating instructions

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.

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 electric tools together with household waste material! In accordance with the European directive 2012/19/EU 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.-22-

K 65 cc Operating voltage

50 Hz 60 Hz 50 Hz 60 Hz Input power continuous operation

Power consumption continuous operation

8,0 A 8.0 A 14,0 A 14,0 A Speed during idling

Saw blade mounting hole

20 mm (51/64 in.) Hose connector diameter

35 mm (1.38 in.) Weight without mains cable, without parallel guide fence 4,5 kg (9.92 lbs) Dimensions (W x L x H)

50 Hz 60 Hz 50 Hz 60 Hz Input power continuous operation

Power consumption continuous operation

14,0 A 14,0 A Speed during idling

Saw blade mounting hole

20 mm (51/64 in.) Hose connector diameter

35 mm (1.38 in.) Weight without mains cable, without parallel guide fence 5,9 kg (13.0 lbs) Dimensions (W x L x H)

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 ist running idle in addition to the trigger time!-23-

2.4.1 Noise emission specifications

Noise emission values determined according to EN 62841-1 and EN 62841-2-5: Sound pressure level L

= 92 dB (A) Uncertainty K

= 3 dB (A) Sound power level

= 100 dB (A) Uncertainty K

= 3 dB (A) The noise measurement was recorded using the saw blade included in the standard equipment.

2.4.2 Vibration specifications

The typical hand-arm vibration according to EN 62841 is less than 2.5 m/s

Portable circular saw K 65 cc complete with: 1 carbide-tipped circular saw blade Ø 185 mm (7 9/32 in.), 24 teeth 1 riving knife / splitter (thickness 1.5 mm / 0.06 in.) 1 service tool in bracket on the machine 1 operating manual 1 folder "Safety instructions" 1 carrying case only for item No. 91B002, 91B030, 91B031, 91B032 1 parallel stop Cross-cutting system KSS 60 cc complete with: 1 carbide-tipped circular saw blade Ø 185 mm (7 9/32 in.), 32 teeth 1 riving knife / splitter (thickness 1.5 mm/ 0.06 in.) 1 service tool in bracket on the machine 1 operating manual 1 folder "Safety instructions" 1 carrying case only for item No. 91B102, 91B130, 91B148 1 parallel stop

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

2.7 Use according to intended purpose

The K 65 cc / KSS 60 cc is exclusively suited for longitudinal and cross cutting of solid wood.-24- 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. Processing wood fibre insulation materials is also possible. The use in industrial continuous operation is not permitted. Any other use than described above is not permissible. The manufacturer shall not be liable for any damage arising from such other use; such use shall also void all guarantee and warranty claims. So as to use the machine as intended, comply with the operating, maintenance and repair instructions specified by Mafell.

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. - 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 EN 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. 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. 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.-25- Instructions on operation: Cutting procedures

Danger - Danger: Never place your hands in the vicinity or in line with the saw blade. With your other hand, support the supplementary handle or the motor casing. If both hands are holding on to the saw they cannot get hurt by the saw 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 anuncontrolled 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.-26- - 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 pre-feed lever 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 pre- feed lever 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. - Risk of injury when changing the saw blade! There is a risk of injury from touching the sharp teeth of the saw blade when changing the saw blade. Wear protective gloves. Exercise caution when changing the saw blade. 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.

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

4.3 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 especially along the grain in soft or hard wood: - Circular saw blade carbide Ø 185 x 2.4 x 20 mm (7 9/32 x 3/32 x 51/64 in.), 16 teeth-27- For cuts along and across the grain in soft or hard wood: - Circular saw blade carbide Ø 185 x 2.4 x 20 mm (7 9/32 x 3/32 x 51/64 in.), 24 teeth For cuts especially across the grain in soft or hard wood: - Circular saw blade carbide Ø 185 x 2.4 x 20 mm (7 9/32 x 3/32 x 51/64 in.), 32 teeth For cuts especially across the grain in soft or hard wood "fine cut": - Circular saw blade carbide Ø 185 x 2.4 x 20 mm (7 9/32 x 3/32 x 51/64 in.), 56 teeth Cutting of wood fibre insulation materials: - Circular saw blade carbide Ø 185 x 2.4 x 20 mm, 56 teeth Cutting of synthetic materials (polystyrene): - Circular saw blade carbide Ø 185 x 2.4 x 20 mm, 24 teeth

4.4 Saw blade change

Danger Pull the power plug during all service work. Risk of injury even if the saw wire is standing still. Wear protective gloves!

• Press the push-button 2 (Fig. 2) and pull the locking lever 3 (Fig. 2) upwards. Now the saw shaft is locked in position and the gearshift lever locked.

• Using the Allen key 4 (brackets Fig. 3) release the flange screw 5 (Fig. 3) counter clockwise. Remove the screw and the front clamping flange 6 (Fig. 3).

• Now you can remove the saw blade after opening the retractable saw guard.

• 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.

4.5 Riving knife/splitter

Danger Pull the power plug during all service work. The riving knife 7 (Fig. 3) prevents the saw blade from jamming during longitudinal cutting. The correct distance to the saw blade is shown in (Fig. 4).

• For adjustment purposes, release the screw 8 (Fig.

3) with the Allen key 4 that is included in the supply

• Adjust the riving knife/splitter by moving it in its longitudinal groove and retighten the screw afterwards.

4.6 Laying the connection cable

Danger While working, pay attention to how the connecting cable is laid. A poorly laid connecting cable can impair safety functions and working functions and come into contact with the tool. How to lay the cable is shown in Fig. 6 by way of example. Lead the connecting cable away from the machine in the direction of the cable sleeve. Always keep the connecting cable as far away as possible from the working tool. For support, use the Velcro fastener on the extraction connection. 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

• Switching on: Press the switch-on lock 9 (Fig. 2) forward to unlock it. Then activate the switch trigger 10 (Fig. 2) while keeping the switch-on lock depressed. As this is a switch without locking device, the machine will only run for as long as this switch trigger lever is pressed.-28- 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 adjusts the motor down in case of overload, i.e. the saw blade will stop. Switch the machine off then. Then switch the machine on again and continue sawing at a reduced feed speed. The setting wheel 11 (Fig. 2) can be used to adjust the saw blade speed in a continuously variable manner between 2700 and 5200 rpm.

• Switching off: For switching off, release the switch trigger 10 (Fig. 2). The built-in automatic brake limits the saw blade slowing time to approx. 1 - 2 s. The switch-on lock automatically takes effect again and secures the portable circular saw against accidental switch-on.

Caution Do not stare into the burning lamp! The power tool is equipped with a light module 21 (Fig. 5). The light module is supplied with power for a certain period of time as soon as the machine is switched on, and is then ready for operation. When the machine is ready for operation, the light module automatically switches the light on when the machine is moved or switches it off when the machine is standing still for longer periods.

5.4 Cutting depth adjustment

The cutting depth is continuously variable between 0 and 66 mm (2.60 in.). Proceed as follows to adjust it:

• Unfasten the clamping lever 12 (Fig. 1).

• Set the cutting depth with the plunge lever 13 (Fig. 1).

• The set depth can be read off the scale 14 (Fig. 1). The bevelled edge of the plunge lever serves as indicator.

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

5.5 Setting for bevel cuts

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

• In order to incline it, bring the machine into home position and support it such that it is possible to tilt the saw unit.

• Release the lever 15 (Fig. 1).

• Adjust the angle according to the scale on the segment for tilting.

• Retighten the lever 15 (Fig. 1) afterwards.

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!-29-

• Unfasten the clamping lever 12 (Fig. 1) and put the machine in the topmost position with plunge lever 13 (Fig. 1).

• Completely open the retractable saw guard with the pre-feed lever 16 (Fig. 1), so that the machine can be placed onto the workpiece to be processed. The saw blade is now freely suspended above the material and can be aligned with the marking.

• Switch on the machine and press the plunge lever 13 (Fig. 1) downwards. This causes the saw blade to plunge vertically into the workpiece. While doing so, the plunge depth can be read off the scale 14 (Fig. 1). 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.

In case of repetitive plunge cuts of the same depth, the plunging depth can be preset. Proceed as follows:

• Set the machine to the desired cutting depth.

• Open the clamping screw 17 (Fig. 2) and set the stop bar 18 (Fig. 2) downwards up to the limit stop.

• Retighten the clamping screw. After completion of the plunge work, set the stop bar into the top position.

5.7 Sawing according to tracings

The retractable marking indicator 19 (Fig. 1) is automatically adjusted for bevel cuts as well. The 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 portable circular saw (see chapter 5.2) and slide the machine evenly forward in the direction of the cut.

• When the cut is completed, switch off the saw by releasing the switch trigger 10 (Fig. 2).

5.8 Sawing with the parallel stop

The parallel stop serves to saw parallel to an already existing edge. The limit stop can be attached to the left or right of the machine. While doing so, the cutting range amounts to 33 - 130 mm (1.30 – 5.12 in.) on the right-hand side (reading indicator "X" Fig. 1) and to 163 - 300 mm (6.42 – 11.81 in.) on the left-hand side (reading edge at indicator edge "Y" Fig. 1). In the range of 163-220 mm (6.42 – 8.66 in.), the machine must be adjusted upwards by approx. 10 mm (0.39 in.) so that the limit stop can be pushed under the motor casing.

• You can adjust the cutting width after releasing the wing screws 20 (Fig. 2) by moving the limit stop accordingly and afterwards retightening the wing screws. In addition, by simply turning it around (guide face for the workpiece edge points upwards), the parallel stop can also be used as double support to improve guidance of the portable circular saw. Now the machine can be guided along a guide that is fastened on the workpiece.

5.9 Working with the roller edge guide

The roller edge guide serves 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. 12 - 40 mm (0.47 – 1.57 in.) and on the left-hand side to approx. 30 – 210 mm (1.18 – 8.27 in.).

• You can adjust the cutting width after releasing the wing screws 20 (Fig. 2) by moving the limit stop accordingly and afterwards retightening the wing screws. 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.-30-

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 Visual signal indication of operating condition The colour of the speed adjusting wheel indicates the machine’s operating state. As long as the machine is not overloaded in terms of output, the speed adjusting wheel permanently lights up green during operation. If the adjusting wheel permanently lights up red, there is a defect (see the Chapter 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 and the speed adjusting wheel lights up red Overtemperature shutdown Allow the machine to cool down Overvoltage switch-off Have power supply checked by an electrician Undervoltage switch-off Machine cannot be switched on and the speed adjusting wheel does not light up No mains voltage Have power supply checked by an electrician Mains fuse defective Have fuse replaced by an electrician Machine cannot be switched on and the speed adjusting wheel lights up green Carbon brushes worn Take the machine to a MAFELL customer service shop Machine stops during cutting and the speed adjusting wheel lights up red Overload switch-off Reduce feed speed Overvoltage switch-off Have power supply checked by an electrician Undervoltage switch-off Machine stops during cutting and the speed adjusting wheel does not light up Mains failure Have mains-side pre-fuses checked by an electrician-31- Defect Cause Elimination Saw blade jams as 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 Heightened caution during sawing, risk of backlash increases. Poor machine guidance (for example due to free-hand guidance) Use parallel guide fence Uneven workpiece surface Straighten the surface 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 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 machine to an external extraction, e.g. portable dust extractor 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-32- 9 Optional accessories

Aerofix suction-clamping-system F-AF 1 Order No. 204 770 - guiding device ML Order No. 204 378

guiding device M Order No. 208 170

Sliding bevel F-WA Order No. 205 357 - Accessories for guide rail: - Screw clamp F-SZ180MM (2 pieces) - Connecting piece F-VS

Rail bag TZ-FST1600 Order No. 207 770 Order No. 204 363 Order No. 095 257

Rail bag kit F80/160 with sliding bevel consisting of: F80 + F160 + connecting piece + sliding bevel + 2 screw clamps + rail bag Order No. 209 592 - Rail bag kit F160/160 consisting of: 2 x F160 + connecting piece + 2 screw clamps + rail bag Order No. 209 591 - Backlash stop F-RS Order No. 202 867 - Roller edge guide UA Order No. 206 073

Flexible hose FXS-L, length 3.2 m Order No. 205276

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

8,0 A 8,0 A 14,0 A 14,0 A Numero di giri a vuoto

8,0 A 8,0 A 14,0 A 14,0 A Numero di giri a vuoto

8,0 A 8,0 A 14,0 A 14,0 A Omdrejningstal i tomgang

8,0 A 8,0 A 14,0 A 14,0 A Omdrejningstal i tomgang

8,0 A: 8,0 A 14,0 A: 14,0 A: Холостой ход

8,0 A: 8,0 A 14,0 A: 14,0 A: Холостой ход

= 92 dB (A) Negotovost

= 100 dB (A) Negotovost K