K55cc - Saw Mafell - Free user manual and instructions

USER MANUAL K55cc Mafell

3D rendering of a mechanical tool with visible blades and base plate (no text or symbols)

MAF02117/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

GB - EC Declaration of Conformity

We herewith confirm that the machine K 55 cc 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

Mechanical power saw with visible cutting edge and blade, no text or symbols present

MAF02159/a

Inhaltsverzeichnis

1 Signs and symbols 16
2 Product information 16
2.1 Manufacturer's data.... 16
2.2 Machine identification 16
2.3 Technical data 17
2.4 Noise emission specifications 17
2.5 Vibration specifications....17
2.6 Scope of supply 17
2.7 Safety devices 18
2.8 Use according to intended purpose....18
2.9 Residual risks 18
3 Safety instructions 18
4 Setting / Adjustment 20
4.1 Mains connection 20
4.2 Chip extraction 20
4.3 Saw blade selection 20
4.4 Saw blade change....20
4.5 Riving knife/splitter 20
5 Operation....21
5.1 Initial operation 21
5.2 Switching on and off 21
5.3 Light....21
5.4 Cutting depth adjustment 21
5.5 Setting for bevel cuts 21
5.6 Plunge cuts....21
5.7 Sawing according to tracings 22
5.8 Sawing with parallel stop 22
5.9 Working with the roller edge guide 22
6 Service and maintenance 22
6.1 Storage 22
7 Troubleshooting....23
8 Special accessories....24
9 Exploded drawing and spare parts list 24

1 Signs and symbols

This symbol appears at places where you will find instructions for your own safety.

Non-compliance with these instructions may result in very serious injuries.

This symbol indicates a potentially hazardous situation.

If this situation is not avoided, the product or objects in its vicinity may get damaged.

This symbol indicates tips for the user and other useful information.

2 Product information

in respect of machines with item No. 918001, 918002, 918020, 918022, 918025, 918030, 918031 or 918032

2.1 Manufacturer's data

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

2.2 Machine identification

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

Protection class II

CE symbol to document compliance with the basic safety and health requirements according to Appendix I of the Machinery Directive.

For EU countries only

Do not dispose of electric tools together with household waste material! In accordance with the European directive 2002/96/EC on waste electrical and electronic equipment and transposition into national law, obsolete electrical tools must be collected separately and recycled in an environmentally-compatible manner.

To reduce the risk of injury, please read the operating instructions.

2.3 Technical data

Universal motor, radio and TV interference suppressed	230 V~50 Hz	240 V~60 Hz	110 V~50 Hz	120 V~60 Hz
Power input (nominal load)	1300 W		1300 W	1300 W
Current at nominal load	6.0 A		12.5 A	11.6 A
Saw blade speed while idling	5700 min ^-1
Saw blade speed at normal load	3300 min ^-1
Cutting depth 0°/30°/45°	58 / 56 / 48 mm
Tilting saw unit 0°– 45°
Saw blade diameter max./min.	168 /157 mm
Largest thickness basic saw blade body	1.2 mm (3/64 in.)
Tool cutting width	1.8 mm (0.070 in.)
Saw blade mounting hole	20 mm
Hose connector diameter	35 mm (1 3/8 in.)
Weight without mains cable, without parallel guide fence	4.1 kg (9.0 lbs)
Dimensions (W x L x H)	234 x 330 x 258 mm

2.4 Noise emission specifications

Noise emission values determined according to EN 60745-1 and EN 60745-2-5:

	Sound power level	Workplace-related emission value
Idling	103 dB (A)	93 dB (A)
Machining	104 dB (A)	91 dB (A)

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

The values stated do not take into consideration any possible series variances and are not suitable for determining the rating levels, as these fluctuate in dependence on the time in service, the respective type of machining and the environmental influences. The noise rating level can therefore only be determined on an individual basis at the machine user's position.

2.5 Vibration specifications

The typical hand-arm vibration is less than 2.5 m/s ^4 .

2.6 Scope of supply

Portable circular saw K 55 cc complete with:

1 carbide-tipped circular saw blade ∅ 168 mm (6 1/4 in.), 24 teeth
1 riving knife/splitter (thickness 1.2 mm/3/64 in.)
1 service tool in bracket on the machine
1 operating manual
1 folder "Safety Instructions"
1 carrying case only for item No. 918002, 918030, 918031, 918032

2.7 Safety devices

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

2.8 Use according to intended purpose

The portable circular saw is exclusively suitable for longitudinal and cross cutting of solid wood.

Panel materials such as chip board, core board and medium density fibre board can also be processed. Use approved saw blades according to EN 847-1.

Any other use than described above is not permissible. The manufacturer cannot be held liable for any damage arising from such other use.

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

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 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!

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.
• 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.

Instructions on operation:

• Do not reach with your hands into the sawing area and do not touch the saw blade. With your other hand, support the supplementary handle or the motor casing.
• Do not reach under the workpiece.
• Adapt the cutting depth to the workpiece thickness.
• Never support the workpiece in your hand or over your leg. Secure the workpiece against a sturdy support.
• Only hold the device by its isolated handle surfaces when carrying out work during which the cutting tool could hit hidden power cables or its own connection cable.
• Always use a limit stop or a straight edge guide for longitudinal cutting.
• Always use correctly sized saw blades with matching receiving bore (e.g. star-shaped or round).
• Never use damaged or incorrect saw blade washers or screws.
• Hold the saw with both hands and bring your arms into a position where you are able to resist the backlash forces. Always keep to the side of the saw blade. Never bring the saw blade in line with your body.
• If the saw blade gets jammed or sawing is interrupted for some other reason, release the on/off switch and keep the saw steady in the material, until the saw blade has come to a

complete standstill. Never try to remove the saw from the workpiece or to pull it backwards while the saw blade is still moving or while a backlash could occur.

• If you would like to restart a saw that is stuck in the workpiece, centre the saw blade in the saw slit and check whether the saw teeth are stuck in the workpiece.
• Support large plates to reduce the risk of backlash caused by a jammed saw blade.
• Do not use any blunt or damaged saw blades.
• Before starting to saw, tighten the cutting depth and cutting angle adjustments.
• Be especially careful when making a “plunge cut” into a concealed area, e.g. into an existing wall.
• 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.
• Check the function of the spring for the lower saw guard. Have the device serviced if lower saw guard and spring do not work properly.
• Only manually open the lower saw guard for special cuts, such as "plunge and angle cuts". Open the lower saw guard using the retracting lever and release the lever as soon as the saw blade has penetrated the workpiece.
• Do not place the saw on the work bench or on the floor without the lower saw guard covering the saw blade.
• Use the saw blade that matches the riving knife/splitter
• Adjust the riving knife / splitter as described in the operating instructions.
• Always use the riving knife / splitter except for "plunge cuts".
• For the riving knife / splitter to function, it has to be located in the saw slit.
• Never operate the saw with a bent riving knife / splitter.
• Examine the workpiece for foreign objects. Never attempt to cut into nails or other metal objects.

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.

4.2 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.).

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 ∅ 168 x 1.8 x 20 mm, 16 teeth

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

- Circular saw blade carbide ∅ 168 x 1.8 x 20 mm, 24 teeth

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

- Circular saw blade carbide ∅ 168 x 1.8 x 20 mm, 32 teeth

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

- Circular saw blade carbide ∅ 168 x 1.8 x 20 mm, 56 teeth

4.4 Saw blade change

Danger

Pull the power plug during all service work.

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

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 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.

- Switching off: Release switch trigger 10 (Fig. 2) to switch off the machine. 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

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 55 mm.

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 scale 14 (Fig. 1). The bevelled edge of the plunge lever serves as indicator.
  • Retighten 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. 1).
• Adjust the angle according to the scale on the segment for tilting.
  • Retighten the lever 15 (Fig. 1) 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!

• Release 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.

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 diagonal cuts, the marking can be viewed through the opening on the left-hand side of the upper saw guard (arrow, fig. 1).

• 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 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). In the range of 163-220 mm, the machine must be adjusted upwards by approx. 10 mm 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 and on the left-hand side to approx. 30 - 210 mm.

- 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.

6.1 Storage

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
Machine stops while cutting is in process	Mains failure	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 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
	Extended operation without extraction	Connect to an external extraction, e.g. portable dust extractor

8 Special accessories

- Saw blade TCT ∅ 168 x 1.8 x 20 (6 1/4 x 5/64 in. x 20 mm), 16 teeth(longitudinal cut)	Order No. 092 476
- Saw blade TCT ∅ 168 x 1.8 x 20 (6 1/4 x 5/64 in. x 20 mm), 24 teeth(longitudinal and crosscuts)	Order No. 092 478
- Saw blade - TCT ∅ 168 x 1.8 x 20 (6 1/4 x 5/64 in. x 20 mm), 32 teeth(cross cut)	Order No. 092 480
- Saw blade - TCT ∅ 168 x 1.8 x 20 (6 1/4 x 5/64 in. x 20 mm), 56 teeth(fine cut)	Order No. 092 482
- Guide rail F80, 800 mm (31 1/2 in.) long	Order No. 204 380
- Guide rail F110, 1100 mm (43 5/16 in.) long	Order No. 204 381
- Guide rail F160, 1600 mm (63 in.) long	Order No. 204 365
- Guide rail F210, 2100 mm (82 11/16 in.) long	Order No. 204 382
- Guide rail F310, 3100 mm (122 in.) long	Order No. 204 383
- Sliding bevel segment F-WA	Order No. 205 357
- Accessories for guide rail:
- Screw clamp F-SZ100MM (2 x)	Order No. 205 399
- Connecting piece F-VS	Order No. 204 363
- Rail bag F160	Order No. 204 626
- Rail bag kit F80/160 with sliding bevel segment consisting of: F80 + F160+ connecting piece + sliding bevel segment + 2 screw clamps + rail bag	Order No. 204 749
- Rail bag kit F160/160 consisting of: 2 x F160 + connecting piece + 2screw clamps + rail bag	Order No. 204 805
- Backlash stop F-RS	Order No. 202 867
- Roller edge guide UA	Order No. 206 073
- parallel stop K55-PA	Order No. 206 825

9 Exploded drawing and spare parts list

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

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