K 65 18M bl - Saw Mafell - Free user manual and instructions

Product type	Cordless portable circular saw / Crosscutting system
Brand	Mafell
Model	K 65 18M bl
Nominal voltage	18 V DC
No-load speed	2450 – 5450 min⁻¹ (adjustable 6 levels)
Cutting depth at 0°	67 mm
Cutting depth at 45°	53 mm
Blade diameter	max 185 mm, min 172 mm
Blade bore	20 mm
Weight without parallel guide	4.4 kg
Dimensions (w × d × h)	246 × 339 × 267 mm
Power supply	CAS Lithium-Ion battery (18 V)
Supplied battery capacity	18 M 99 LiHD (depending on version)
Supplied charger	APS M (depending on version)
Main functions	Rip cut, cross cut, plunge cut, bevel cut (0–45°), progressive depth adjustment, variable speed, LED light, automatic brake
Included accessories	16-tooth carbide blade, riving knife, parallel guide, dust bag, transport case, service tool
Safety	Fixed upper protective guard, lower movable guard, riving knife, lock-off switch, electric brake
Maintenance	Regular cleaning, lubrication with Mafell special grease ref. 049040, servicing by authorized service center
Spare parts	Available at www.mafell.com (exploded view online)
Repairability index	Not communicated, but spare parts available

Frequently Asked Questions - K 65 18M bl Mafell

How to change the saw blade?

First remove the battery. Actuate the push button and locking lever to lock the spindle. Loosen the flange screw with the supplied wrench (turn counterclockwise). Open the movable guard and remove the blade. Mount the new blade respecting the rotation direction (arrow on blade). Replace the flange and tighten the screw clockwise. Wear protective gloves.

How to adjust the cutting depth?

Loosen the clamping lever (12). Use the plunge lever (13) to adjust the depth; the graduated scale (14) shows the value. The depth should exceed the material thickness by 2 to 5 mm. Retighten the clamping lever.

How to perform a plunge cut?

Set the depth to the highest position. Open the movable guard completely using the lever (16). Place the tool on the workpiece, align the blade with the cut line. Start the tool and lower the plunge lever (13) to plunge the blade vertically. Advance gently. The riving knife rises automatically.

Which battery can I use?

Use only CAS (Cordless Alliance System) 18 V battery packs, for example Mafell 18 M 99 LiHD or 18 M 144 LiHD models. Use only Mafell APS 18 chargers.

How to maintain the saw?

Clean the tool regularly, especially the adjustment devices. Lubricate the lubrication points with Mafell special grease ref. 049040. The ball bearings are lubricated for life. For servicing, contact Mafell after-sales service.

What are the safety devices?

The saw is equipped with a fixed upper protective guard, a lower movable protective guard, a riving knife, an automatic electric brake, and a lock-off switch. Never remove or disable these devices.

Can I cut metal with this saw?

No, intended use is limited to solid wood, wood-based panels (MDF, particleboard) and insulating materials made of wood fibers. Do not use HSS or metal-cutting blades.

How to adjust the speed?

Use the adjustment wheel (11) to select one of 6 speeds (2450 to 5450 min⁻¹). Adapt the speed to the material: levels 1-2 for plastics, 3-6 for wood, 4-6 for coated panels.

What to do if the blade jams?

Release the switch immediately. Remove the tool from the workpiece. Check the cause: feed too fast, dull blade, or tensions in the workpiece. Reduce feed, change the blade, or use a wedge to widen the cut.

How to transport the battery?

Li-ion batteries are subject to dangerous goods regulations. For third-party transport, pack the battery intact, cover the contacts, and prevent movement. For personal use, road transport is permitted without additional measures.

USER MANUAL K 65 18M bl Mafell

Portable circular saw / cross-cutting system

Translation of the original operating 22 instructions

Mechanical power saw assembly (no visible text or symbols)

MAF02134/a

Mechanical cutting tool with a flat blade and circular cutter (no visible text or symbols)

MAF02155/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

13 16 14 X Y 12

MAF02135/c

3 18 2 9 10 11 15 17 21 22

MAF02136/c

1 4 20 8 7 6 5 36 19 3

MAF02156/a

max. 5 max. 5

MAF00806/a

5 100% 75% 50% 25% =<20%

MAF02153/a

GB - EC Declaration of Conformity

We herewith confirm that the machine K65 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

GB - EC Declaration of Conformity

We herewith confirm that the machine KSS60 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	23
2	Product information	23
2.1	Manufacturer's data	23
2.2	Rechargeable battery specifications	23
2.3	Machine identification	23
2.4	Technical data	24
2.5	Emissions	25
2.6	Scope of supply	25
2.7	Safety devices	26
2.8	Use according to intended purpose	26
2.9	Residual risks	26
3	Safety instructions	26
4	Setting / Adjustment	29
4.1	Charging the rechargeable battery	29
4.2	Fitting the rechargeable battery	29
4.3	Removing the rechargeable battery	29
4.4	Chip extraction	30
4.5	Saw blade selection	30
4.6	Saw blade change	30
4.7	Riving knife/splitter	30
5	Operation	30
5.1	Initial operation	30
5.2	Switching on and off	30
5.3	Light	31
5.4	Cutting depth adjustment	31
5.5	Setting for bevel cuts	31
5.6	Plunge cuts	31
5.7	Sawing according to tracings	32
5.8	Sawing with the parallel stop	32
5.9	Working with the roller edge guide	32
6	Service and maintenance	32
6.1	Storage	32
6.2	Transport	33
6.3	Disposal of rechargeable batteries/batteries	33
7	Troubleshooting	33
8	Optional accessories	35
9	Exploded drawing and spare parts list	36

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

K 65 18M bl: Art.-No. 91D801, 91D802, 91D803, 91D821

KSS60 18M bl: Art.-No. 91D901, 91D902, 91D903, 91D921

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

K 65 18M bl

Type of motor

Operating voltage

Speed during idling

Cutting depth 0° /30° /45°

Tilting saw unit

Saw blade diameter max./min.

Saw blade base body thickness

Tool cutting width

Saw blade mounting hole

Hose connector diameter

Weight with rechargeable battery (without parallel stop)

Dimensions (W x L x H)

brushless

18 V DC

2450 - 5450 rpm

67 / 62 / 53 mm (2.64 / 2.44 / 2.09 in.)

0^ - 45^

185 / 172 mm (7.28 / 6.77 in.)

1.2 mm (3/64 in.)

1.8 mm (0.07 in.)

20 mm (0.79 in.)

35 mm (1.38 in.)

4.4 kg (9.70 lbs)

246 x 339 x 267 mm (9.68 x 13.35 x 10.51 in.)

KSS60 18M bl

Type of motor

Operating voltage

Speed during idling

Cutting depth 0° /30° /45°

Tilting saw unit

Saw blade diameter max./min.

Saw blade body thickness

Tool cutting width

Saw blade mounting hole

Hose connector diameter

Weight with rechargeable battery (without parallel stop)

Dimensions (W x L x H)

as cross-cutting system

Cutting depth 0° /30° /45°

Cutting length at 12/49.5 mm (0.47/1.95 in.)

workpiece thickness

Weight with guiding device and rechargeable battery

Dimensions incl. guiding device (WxLxH)

brushless

18 V DC

2450 - 5450 rpm

67 / 62 / 53 mm (2.64 / 2.44 / 2.09 in.)

0^ - 45^

185 / 172 mm (7.28 / 6.77 in.)

1.2 mm (3/64 in.)

1.8 mm (0.07 in.)

20 mm (0.79 in.)

35 mm (1.38 in.)

4,4 kg (9.7 lbs)

246 x 339 x 267 mm (9.68 x 13.35 x 10.51 in.)

61 / 56 / 47 mm (2.40 / 2.20 / 1.85 in.)

470/400 mm (18.50/15.75 in.)

5.8 kg (12.79 lbs)

260 x 769 x 277 mm (10.24 x 30.27 x 10.90 in.)

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

$$ \mathrm{L} _ {\mathrm{PA}} = 9 4 \mathrm{dB(A)} $$

Uncertainty K

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

Sound power level L

$$ _ {W A} = 1 0 2 \mathrm{dB(A)} $$

Uncertainty

$$ \mathrm{K} _ {\mathrm{WA}} = 3 \mathrm{dB(A)} $$

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 ^4 .

2.6 Scope of supply

Portable circular saw K 65 18M bl complete with:

1 carbide-tipped circular saw blade ∅ 185 mm (7.28 in.), 16 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
1 parallel stop
1 chip bag
1 charger APS M with item number 91D801, 91D821
2 chargers APS 18M 99 with item number 91D801, 91D821

Cross-cutting system KSS60 18M bl complete with:

1 carbide-tipped circular saw blade ∅ 185 mm (7.28 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
1 parallel stop

1 chip bag
1 charger APS M for Art.No. 91D901, 91D921
2 chargers APS 18M 99 LiHD for Art.No. 91D901, 91D921

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 K65 18M bl / KSS60 18M bl 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. Only use the saw blades approved by Mafell in accordance with EN 847-1 in the specified -range

The use of wood fibre insulation materials 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.

Only use saw blades with a speed marking that corresponds to or is higher than the speed specified on the power tool

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.

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 stipulated for the respective operating sequence and do not effect any modifications on the machine that could impair safety.
• Examine the workpiece for foreign objects. Never attempt to cut into nails or other metal objects.
• 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

• Prior to every use, check whether the lower saw guard is closing properly. Do not use the saw if the lower saw guard is not freely movable and does not close immediately. Never clamp or tie down the lower saw guard in an open position. If the saw is dropped inadvertently, the lower saw guard can get bent. Open the saw guard with the pre-feed lever and ensure that it moves freely and touches neither saw blade nor other parts irrespective of the cutting angle and depth.
• 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.
• Only manually open the lower saw guard for special cuts, such as "plunge and angle cuts". Open the lower saw guard using the pre-feed lever and release the lever as soon as the saw blade has penetrated the workpiece. During all other sawing work, the lower saw guard is to 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 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 next to 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 21 (Fig. 2) and pull it out of the battery guide.

Do not use force to do so.

4.4 Chip extraction

Danger

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

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

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

The chip bag can be used for self-generated dust extraction when briefly carrying out work that generates a low amount of dust.

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 especially along the grain in soft or hard wood:

- Circular saw blade carbide ∅ 185 x 1.8 x 20 mm (7.28 x 0.07 x 0.79 in.), 16 teeth

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

- Circular saw blade carbide ∅ 185 x 1.8 x 20 mm (7.28 x 0.07 x 0.79 in.), 32 teeth

4.6 Saw blade change

Danger

Unplug the rechargeable battery for 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 shift 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.

4.7 Riving knife/splitter

Danger

Unplug the rechargeable battery for all service work.

The riving knife/splitter 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 (Fig. 3).
• Adjust the riving knife/splitter by moving it in its longitudinal groove and retighten the screw afterwards.

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: Press the switch-on lock 9 (Fig. 2) forward to unlock it. Then actuate switch trigger 10 (Fig. 2) when the switch-on lock is pressed.

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

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

In addition, this electronic system 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.

Warming of the machine leads to faster overload shutdown.

With the setting wheel 11 (Fig. 2) you can adjust the saw speed between 2450 and 5450 rpm.

Level Speed rpm
1 2450
2	3050
3	3650
4 4250
5 4850
6 5450

Material groups

- PVC, Plexi, PA

- Level: 1 - 6

- Hardwood, softwood, plywood

- Level: 3 - 6

- Coated panel materials

- Level: 4 - 6

- Fibre cement board

- Level: 3 - 5

- 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.

5.3 Light

The power tool is equipped with a light module 36 (Fig. 3).

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

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. 2).
• Adjust the angle according to the scale on the segment for tilting.
  • Retighten the lever 15 (Fig. 2) afterwards.

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 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. 3) 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 on the right-hand side (reading indicator "X" Fig. 1) and to 163 - 300 mm on the left-hand side (reading edge at indicator edge "Y" Fig. 1).

- You can adjust the cutting width after releasing the wing screws 20 (Fig. 3) 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. 3) by moving the limit stop accordingly and afterwards retightening the wing screws.

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 33.

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 Elimination
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 22 (Fig. 2 + 5).If only one LED is still glowing, recharge the rechargeable battery.
Overload, machine switches off. A	sustained load has overheated the machine or the rechargeable battery. A warning signal is sounded (beep tone). As long as the machine or the rechargeable battery have not cooled down, every further attempt to switch on the machine will result in another beep tone.	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. A warning signal is sounded (beep tone). 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
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	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 ejectionUse dry wood
	Extended operation without extraction	Connect machine to an external extraction, e.g. portable dust extractor
Sudden smoke emission from the motor casing	Overload of the machine's electronic system	Interrupt the power supply by removing the battery pack. The smoke emission stops.Do not insert a rechargeable battery! Avoid inhaling the smoke!
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 ∅ 185 x 1.8 x 20 mm, 16 teeth (longitudinal cut) Order No. 092494
• Saw blade carbide ∅ 185 x 1.8 x 20 mm, 32 teeth (cross cut) Order No. 092493
• Guide rail F80, 800 mm long Order No. 204380
• Guide rail F110, 1100 mm long Order No. 204381
• Guide rail F160, 1600 mm long Order No. 204365
• Guide rail F210, 2100 mm long Order No. 204382
• Guide rail F310, 3100 mm long Order No. 204383
• guiding device M Order No. 208170
• guiding device ML Order No. 204378
• Sliding bevel F-WA Order No. 205357
• Accessories for guide rail:
• Screw clamp F-SZ180MM (2 x) Order No. 207770
• Connecting piece F-VS Order No. 204363
• Rail bag TZ-FST1600 Order No. 095257

- Rail bag kit F80/160 with sliding bevel consisting of: F80 + F160 + connecting Order No. 209592 piece + sliding bevel + 2 screw clamps + rail bag

- Rail bag kit F160/160 consisting of: 2 x F160 + connecting piece + 2 screw Order No. 209591 clamps + rail bag

- Roller edge guide UA Order No. 206073

- Aerofix suction-clamping-system F-AF 1 consisting of: Rail 1.3 m, adapter for Order No. 204770 top and bottom, flexible hose

- Rechargeable power station APS M Order No. 094492

- Rechargeable power station APS M GB Order No. 094493

- Rechargeable battery PowerTank 18 M 99 LiHD Order No. 094503

• Rechargeable battery PowerTank 18 M 144 LiHD Order No. 094498
• 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
• 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
• Chip bag Order No. 206921

9 Exploded drawing and spare parts list

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

Sommaire

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MAFELL AG

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