KSS 300 - Saw Mafell - Free user manual and instructions

USER MANUAL KSS 300 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 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.-20-

50 Hz 50 Hz Input power continuous operation

900 W 1000 W Power consumption continuous operation

4,1 A 9,1 A Speed during idling

42/36/29 mm ( 1 21/32, 1 27/64, 1 9/64 in. ) Swivelling saw unit

20 mm Hose connector diameter

50 Hz 50 Hz Input power continuous operation

900 W 1000 W Power consumption continuous operation

4,1 A 9,1 A Speed during idling

42/29 mm ( 1 21/32, 1 9/64 in. ) Tilting saw unit

120/112 mm ( 4 23/32, 4 13/32 in. ) Largest thickness basic saw blade body

Saw blade mounting hole

20 mm Hose connector diameter

28 mm ( 1 7/64 in. ) Weight without mains cable, without parallel guide fence

200 x 550 x 200 mm ( 7 7/8 x 21 21/32 x 7 7/8 in. ) as cross-cutting system

40/27 mm ( 1 9/16, 1 1/16 in. ) Cutting length at 12/40 mm ( ½ / 1 ½ in. ) workpiece thickness

337/292 mm ( 13 ¼, 11 ½ in. ) Weight with guiding device, without mains cable

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.-21- 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 62841-1 and EN 62841-2-5: Sound pressure level L

= 95 dB (A) Uncertainty

= 3,0 dB (A) Sound power level L

= 103 dB (A) Uncertainty K

= 3,0 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 is less than 2.5 m/s

Portable circular saw KSP 40 Flexistem complete with: 1 carbide tipped circular saw blade Ø 120 mm, 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 1 FLEXI rail FX 140 for cutting length max. 140 cm ( 55 in. ) Cross-cuting system KSS 300 complete with: 1 carbide-tipped circular saw blade Ø 120 mm ( 4 ¾ in. ) , 40 teeth 1 riving knife / splitter (thickness 1.2 mm / 3/64 in.) 1 hose connector 1 parallel guide fence 1 service tool in bracket on the machine 1 carrying case max 1 operating manual 1 folder “Safety Instructions” 2 clamping claws on item No. 916702, 916730, 916731, 916732, 916735 1 FLEXI rail FX 140 for cutting length max. 140 cm ( 55 in. ) on item No. 916702, 916730, 916731, 916732, 916735-22-

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

2.7 Use according to intended purpose

The KSP 40 Flexistem / KSS 300 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. Processing wood fibre insulation materials and synthetic materials (polystyrene) is also possible. 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.

Danger Even if used in accordance with its intended purpose and despite conforming with the safety instructions, residual risks caused by the intended use 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. - 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 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.-23- - 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

- 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 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-24- 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 Mains connection

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

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.).

4.3 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:-25- For cuts along and across the grain in soft or hard wood: - HM circular saw blade Ø 120 x 1.8 x 20 mm ( 4 ¾ x 5/64 in. x 20 mm ), 24 teeth For cuts especially along the grain in soft or hard wood: - HM circular saw blade Ø 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: - HM circular saw blade Ø 120 x 1.8 x 20 mm ( 4 ¾ x 5/64 in. x 20 mm ), 40 teeth For cuts in laminate: - HM circular saw blade Ø 120 x 1.8 x 20 mm ( 4 ¾ x 5/64 in x 20 mm ), 40 trapezoidal teeth Cutting of wood fibre insulation materials: - Circular saw blade carbide Ø 120 x 1.8 x 20 mm, 40 teeth Cutting of synthetic materials (polystyrene): - Circular saw blade carbide Ø 120 x 1.8 x 20 mm, 24 teeth Order No. see special accessories.

Danger Pull the power plug during 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.

2) with the machine running! The

machine may get damaged.

4.5 Riving knife/splitter

Danger Pull the power plug during 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

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 off: To switch off, release the switch trigger.

5.3 Cutting depth adjustment

The cutting depth is continuously variable between 0 and 42 mm. 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.-26-

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 10 (Fig. 2).

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

• Afterwards, tighten the wing screws 10.

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!

• Open the retractable saw guard with the lever 2 (Fig. 3), so that the machine can be placed onto the workpiece to be processed. The saw blade is now running freely above the material and can be aligned for tracing.

• Press the plunge lever 6 (Fig. 2) downwards, so that the saw blade plunges vertically into the workpiece. The plunging depth can be read from 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.

5.6 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.

5.7 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.

5.8 Sawing with the parallel stop

When making parallel cuts, the parallel guide fence 4 (Fig. 1) serves to saw parallel to an already existing edge. The guide fence can be attached to the left or right of the machine. The cutting range on the right--27- 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. ). In the range of 175-220 mm, the machine must be adjusted upwards by approx. 10 mm so that the limit stop can be pushed under the motor casing.

• Once you have unfastened the wing screws you can adjust the cutting width 9 (Fig. 2) by moving the guide fence accordingly and afterwards retightening the wing screws. Additionally, the parallel limit stop can also be used as double support to improve machine guidance by simply turning it around (guide face for the workpiece edge is pointing upwards). Now the machine can be guided along a lath fastened on the workpiece.

5.9 Sawing according to tracings

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 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.

If the machine is not used for a longer period of time, it has to be carefully cleaned. Spray bright metal parts with a rust inhibitor. 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 at 230 V~ Machine switches off automatically during idling or stops during the cutting process

Check mains-side pre-fuse Machine overloaded Switch machine off and on again Reduce feed speed at 230 V~ The speed decreased during cutting.

Reduce feed Blunt saw blade Sharpen or replace saw blade-28- Defect Cause Elimination at 110 / 120 V~ Machine stops while cutting is in process

Check mains back-up fuses Machine overloaded Reduce feed speed 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

Poor machine guidance Use parallel guide fence 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

Extended operation without exhaustion 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 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 Optional accessories

Saw blade carbide Ø 120 x 1.8 x 20 mm, 12 teeth, WZ (longitudinal cut) Order No. 092560 - Saw blade carbide Ø 120 x 1.8 x 20 mm, 24 teeth, WZ (longitudinal and cross cuts) / Cutting of synthetic materials (polystyrene) Order No. 092558

FLEXI rail FX 140, cpl. Order No. 204372

- Accessories for FLEXI rail:

Screw clamp Order No. 093281 - guiding device S Order No. 208169

Chip bag complete Order No. 206787

= 3,0 dB (A) Geluidsniveau L

= 95 dB (A) Negotovost K

= 103 dB (A) Negotovost K