K 105-18 - Saw Mafell - Free user manual and instructions

USER MANUAL K 105-18 Mafell

3D rendering of a cut-out saw with visible blade and base plate (no text or symbols)

MAF02452/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 105-18 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	24
2	Product information	24
2.1	Manufacturer's data	24
2.2	Information on the rechargeable battery	24
2.3	Machine identification	24
2.4	Technical data	25
2.5	Emissions	25
2.6	Scope of supply	26
2.7	Safety devices	26
2.8	Intended use	26
2.9	Residual risks	26
3	General safety instructions for power tools	27
4	Safety information for circular saws	27
4.1	Sawing method	27
4.2	Kickback - reasons and corresponding safety instructions	27
4.3	Function of the lower guard	28
4.4	Function of the riving knife/splitter	28
5	Specific safety regulations	28
5.1	Working range	28
5.2	Instructions on service and maintenance	29
5.3	Note on rechargeable batteries	29
6	Layout	29
6.1	Depicted components	29
7	Setting / adjustment	30
7.1	Charging the rechargeable battery	30
7.2	Fitting the rechargeable battery	30
7.3	Removing the rechargeable battery	30
7.4	Chip extraction	31
7.5	Saw blade selection	31
7.6	Saw blade change	31
7.7	Riving knife/splitter	31
8	Operation	32
8.1	Putting into operation	32
8.2	Switching on and off	32
8.3	Light	33
8.4	Cutting depth adjustment	33
8.5	Setting for bevel cuts	33
8.6	Plunge cuts	33
8.7	Sawing according to tracings	34
8.8	Sawing with the parallel stop	34
8.9	Working with the roller edge guide	34

8.10 Sawing of sandwich panels 34
9 Service and maintenance....34
9.1 Storage 34
9.2 Transport 35
9.3 Disposal of rechargeable batteries/batteries 35
10 Troubleshooting....35
11 Optional accessories....37
12 Exploded drawing and spare parts list 37

1 Signs and symbols

This symbol is found in all places where you will find information for your safety.

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

This symbol indicates a potentially hazardous situation.

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

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

2 Product information

for machine with Art.-No. 91D302, 91D303

2.1 Manufacturer's data

MAFELL AG, Beffendorfer Straße 4, D-78727 Oberndorf / Neckar, Phone [phone], Fax [phone], e-mail: [e-mail], Homepage www.mafell.com

2.2 Information on the rechargeable battery

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 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.

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

Type of motor	brushless
Operating voltage	18 V DC
Speed during idling	2800 - 5200 min ^-1
Cutting depth 0°/30°/45°/60°	110/94/77/55 mm (4 21/64 | 3 45/64 | 3 1/32 | 2 11/64 inches)
Tilting saw unit	0°- 60°
Saw blade diameter 280 mm (11 1/32 inches)
Saw blade base body thickness	1.8 mm (5/64 inches)
Tool cutting width 2.8 mm (7/64 inches)
Saw blade mounting hole	30 mm (1 3/16 inches)
Hose connector diameter	35 mm (1 3/8 inches)
Weight with rechargeable battery (without parallel stop)	9.3 kg (20.50 lbs)
Dimensions (W x L x H)	297 x 450 x 327 mm (11 11/16 x 17 23/32 x 12 7/8 inches)

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 L _PA = 94 dB (A)

Uncertainty K _PA = 3 dB (A)

Sound power level L_WA = 102 dB (A)

Uncertainty K _WA = 3 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 according to EN 62841 is less than 2.5 m/s ^2 .

2.6 Scope of supply

Portable circular saw K 105-18 complete with:

1 carbide-tipped circular saw blade ∅ 280 mm (11 1/32 inches), 15 teeth
1 riving knife/splitter (thickness 2.2 mm (3/32 inches))
1 parallel guide fence
1 service tool in bracket on the machine
1 operating manual
1 folder "Safety instructions"

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 Intended use

The K 105-18 is suitable for longitudinal and cross cutting of solid wood. Processing of panel materials (chip board, core board and Mdf board), wood fibre insulation material and synthetic materials (polystyrene) is also possible. In addition, the K 105-18 is suitable for processing sandwich panels.

Use saw blades according to EN 847-1 approved for the respective purpose.

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.

Only use original Mafell / CAS rechargeable batteries and accessories.

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.
• Touching live parts with the housing open and the rechargeable battery 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 General safety instructions for power tools

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).

4 Safety information for circular saws

4.1 Sawing method

• 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.

4.2 Kickback - reasons and corresponding safety instructions

• 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.

4.3 Function of the lower guard

• 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.

4.4 Function of the riving knife/splitter

• 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.

5 Specific safety regulations

5.1 Working range

General instructions:

• Children and adolescents must not operate this saw. This rule does not apply to young persons receiving training under expert supervision.
• Ensure that no persons are within the danger zone.
• Never work without the protection devices prescribed for the respective operating sequence and do not make any changes to the saw that could impair safety.
• Always wear your personal protective equipment while working (hearing protection, safety goggles, dust mask, safety footwear).
• Provide a free and non-slip location with adequate lighting.
• Examine the workpiece for foreign objects.
• Only saw into metal parts, e.g. nails, with a suitable saw blade.
• Do not use any cracked and warped saw blades.
• Do not use any blunt saw blades as they cause an excessive load on the motor.

• Do not use any saw blades made of high-alloy high-speed steel (HSS saw blades).

• Do not use any saw blades which are not suitable for the saw blade's idling speed.

• Do not use any grinding disks.
• Use a residual current circuit breaker when using the machine outdoors.
• Immediately replace damaged cables or plugs. 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.

5.2 Instructions on service and maintenance

• Clean the saw regularly, in particular the adjusting devices and guides. This is an important safety factor.
• Pay attention during transport and storage that the cable does not wind around the machine and avoid sharp bends in the cable.
• Risk of injury when changing the saw blade! Wear protective gloves when you change the saw blade and proceed with caution. You can get injured when you touch the sharp teeth of the saw blade.
• Only use original MAFELL spare parts and accessories. Otherwise, the manufacturer will not accept any warranty claims and cannot be held liable.

5.3 Note on rechargeable batteries

• 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.

• Remove the rechargeable batteries when the machine is put down, transported or stored without supervision.
• Ensure that the saw is switched off when you inserting the rechargeable battery.

6 Layout

6.1 Depicted components

(see Fig. 1-5)

(1) Pre-feed lever
(2) Push-button
(3) Hose connector
(4) Screw
(5) Hexagon screwdriver
(6) Plunge lever
(7) Switch lock
(8) Shift lever
(9) Wing screws
(10) Clamping lever
(11) Push-button
(12) Front clamping flange
(13) Scale
(14) Clamping screw
(15) Riving knife/splitter
(16) Stop bar
(17) Parallel guide fence
(18) Flange screw
(19) Locking lever
(20) Setting wheel
(22) Rechargeable battery
(23) Light module

(21) Unlocking mechanism rechargeable battery

7 Setting / adjustment

7.1 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 original Mafell / CAS rechargeable batteries and chargers.

Before using a new machine, first of all charge the rechargeable battery.

The charging operation is described in the instructions supplied with the charger.

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.

7.2 Fitting the rechargeable battery

Before inserting, check whether the rated voltage of the rechargeable battery agrees with the information specified on the machine.

Danger

There is an explosion hazard if the rechargeable battery is replaced incorrectly. Only replace the rechargeable battery with the same or equivalent type.

Slide the two rechargeable batteries one after the other into the two battery guides - next to the handle and at the rear of the handle - until the rechargeable batteries perceptibly engage.

Before using the machine, convince yourself that the rechargeable batteries are firmly seated in the machine.

7.3 Removing the rechargeable battery

Unlock the rechargeable batteries one after the other by pressing push button 21 (Fig. 5) and pull them out.

Do not use force to do so.

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

7.5 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 along and across the grain in soft and hard wood:

- Saw blade KSB-WU280 GT, circular saw blade carbide ∅ 280 x 2.8 x 30 mm, 28 teeth

For cuts especially along the grain in soft and hard wood:

- Saw blade KSB-WL280 GT, circular saw blade carbide ∅ 280 x 2.8 x 30 mm, 15 teeth

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

- Saw blade KSB-WF280 GT, circular saw blade carbide ∅ 280 x 2.8 x 30 mm, 56 teeth

Cutting of wood fibre insulation materials:

- Saw blade KSB-WF280 GT, circular saw blade carbide ∅ 280 x 2.8 x 30 mm, 56 teeth

Cutting of synthetic materials (polystyrene):

- Saw blade KSB-WU280 GT, circular saw blade carbide ∅ 280 x 2.8 x 30 mm, 28 teeth

Cutting of sandwich panels with cores made of polyurethane/polyisocyanurate foam (PUR/PIR):

- Saw blade KSB-SP280, circular saw blade carbide ∅ 280 x 2.6 x 30 mm, 52 teeth

7.6 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 19 upwards. Now the saw shaft is locked in position and the gearshift lever locked. You can lock the retractable saw guard in an open position with the aid of the pre-feed lever 1 (Fig. 2) or manually to make the tool change easier.
• Using the Allen key 5 (bracket Fig. 2), release the flange screw 18 (Fig. 3) counter clockwise. Now remove both the screw and the front clamping flange 12.
• You can now remove the saw blade.
• The clamping flanges must be free of adhering parts.
• Pay attention to the sense of rotation when inserting the saw blade.
• Afterwards, push on the clamping flange, apply the flange screw and tighten it by turning it clockwise.
• Close the retractable saw guard. To do so, press the locking lever 19 (Fig. 2) downwards.

7.7 Riving knife/splitter

Danger

Unplug the rechargeable battery for all service work.

The riving knife/splitter 15 (Fig. 3) prevents the saw blade from jamming during longitudinal cutting. 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/splitter reverts to its normal position. The correct distance to the saw blade is shown in (Fig. 4).

- For adjustment purposes, release the screw 4 (Fig. 3) with the Allen key 5 that is included in the supply (Fig. 2)

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

Due to the riving knife/splitter (flipping wedge) which is under spring tension it is possible to dispense with the previously necessary mounting and dismounting of the riving knife/splitter to be able to execute plunge cuts at all.

8 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.

8.1 Putting into operation

Personnel entrusted to work with the machine must be made aware of the operating instructions, calling particular attention to the chapter "Safety instructions".

8.2 Switching on and off

- Switching on: Press the switch-on lock 7 (Fig. 2) forward to unlock it. Then, with the switch-on lock depressed, press shift lever 8.

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

The setting wheel 20 (Fig. 2) can be used to adjust the saw blade speed in a continuously variable manner between 2800 and 5200 rpm.

A suitable setting of the speed prevents the saw teeth from overheating and extends the life time of the saw blades.

Please refer to the details below for the appropriate setting of the saw blade speed for your intended use and material.

Level Speed rpm
1 2800
2 3250
3 3700
4	4100
5	4750
6 5200

Material groups

- Hardwood, softwood, plywood

- Level: 4 - 6

- Coated panel materials

- Level: 4 - 6

- Soft fibre

- Level: 6

- Sandwich panels

- Level: 4

- Plastic (polystyrene)

- Level: 1 - 2

The instructions for cutting wood can also be used for cutting structural plastic materials. When cutting plastic materials, always make a test cut to determine whether the saw will cause the material to melt. If required, adapt the cutting speed and/or the feed rate and/or the saw blade to minimise/avoid melting.

- Switching off: To switch off, release the shift lever 8. The built-in automatic brake limits the saw blade slowing time to approx. 5 s. The switch-on lock automatically takes effect again and secures the portable circular saw against accidental switch-on.

8.3 Light

The power tool is equipped with a light module 23 (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.

If the machine is at a standstill for a longer period of time, the light switches off automatically.

8.4 Cutting depth adjustment

The cutting depth is continuously variable between 0 and 110 mm.

Proceed as follows:

• Press the push-button 11 (Fig. 1) and adjust the cutting depth with the plunge lever 6.
• The cutting depth can be read off scale 13 on the cover. The surface of plunge lever 6 with the red background 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.

8.5 Setting for bevel cuts

For bevel cuts, the saw unit can be set to any angle between 0^ and 60^ .

• In order to incline it, bring the machine into home position and support it such that it is possible to tilt the saw unit.
  • Unfasten the wing nut 10 (Fig. 2)
• Adjust the angle according to the scale on the segment for tilting.
  • Afterwards, tighten the wing bolt 10.

8.6 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!

• Press the push-button 11 (Fig. 1) and put the machine in the topmost position with plunge lever 6.
• Completely open the retractable saw guard with the pre-feed lever 1 (Fig. 2), 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 6 (Fig. 1) downwards. This causes the saw blade to plunge vertically into the workpiece. The plunging depth can be read from scale 13. The riving knife/splitter swings up and away during the plunging process. As soon as the slit behind the saw blade is cleared during the forward motion of the machine, the riving knife/splitter reverts to its normal position. Due to the riving knife/splitter (flipping wedge) which is under spring tension it is possible to dispense with the previously necessary mounting and dismounting of the riving knife/splitter to be able to execute plunge cuts at all.

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 14 (Fig. 2) and set the stop bar 16 downwards up to the limit stop.
• Retighten the clamping screw. After completion of the plunge work, set the stop bar into the top position.

8.7 Sawing according to tracings

The pivoting part is equipped with a tracing edge for 0^ - 60^ . This tracing edge corresponds to the saw blade's inside. For bevel cuts, the tracing can be viewed through the opening below the plunge lever 6.

• 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 8.2) 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 8 (Fig. 2)

8.8 Sawing with the parallel stop

The parallel stop 17 (Fig. 2) serves to cut 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 49 - 200 mm (1 59/64 - 7 7/8 in.) and on the left-hand side to 195 - 405 mm (7 43/64 - 15 15/16 in.). In the range 195 - 260 mm (7 43/64 - 10 15/64 in.), the machine must be set approx. 10 mm (25/64 in.) to the top, so that the machine can be pushed under the motor casing.

- You can adjust the cutting width after releasing the wing screws 9 (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 lath that is fastened on the workpiece.

8.9 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. 14 - 48 mm (35/64 - 1 57/64 in.) and on the left-hand side to approx. 40 - 280 mm (1 37/64 - 11 15/64 in.).

- You can adjust the cutting width after releasing the wing screws 9 (Fig. 2) by moving the limit stop accordingly and afterwards retightening the wing screws.

8.10 Sawing of sandwich panels

Danger

Chips from sandwich panels consisting of steel/metal chips and plastic foam dust create an increased risk of deposits in problematic areas of the machine.

Thoroughly clean the machine after performing such work and check the functioning of the safety devices, e. g. the closing motion of the mobile lower guard.

Sandwich panels must be processed with a saw blade in accordance with chapter 7.5.

It is possible to process sandwich panels for inside and outside walls, ceilings and roofs up to a thickness of 100 mm, with top surfaces made of sheet steel / aluminium with a thickness of 0.4 – 0.8 mm and a core made of polyurethane/polyisocyanurate foam.

The following contours can be sawed: Line, microwave, microline, groove, microgroove, smooth, trapezoid.

9 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.

9.1 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.

9.2 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.

9.3 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 2012/19/EC, power tools that are no longer serviceable, and according to the Battery Regulation (EU) 2023/1542, defective or used rechargeable batteries/batteries must be collected separately and recycled in an environmentally sound manner.

Rechargeable batteries/batteries:

Li-Ion:

Please comply with the information in Section "Transport", page 35.

Subject to changes.

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

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
	The second rechargeable battery is missing	Insert both rechargeable batteries correctly and ensure they are properly seated
Rechargeable battery almost empty, an LED on the rechargeable battery is flashing.	Electronic system protects the rechargeable battery from deep discharge.	To check its state of charge, press the button on the rechargeable battery.If only one LED is still glowing, recharge the rechargeable battery.
Defect Cause Elimination
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	Heightened caution during sawing, risk of backlash increases.
	Poor machine 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
	Extended cutting 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
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!
Plastic melts during sawing	Blunt or incorrect saw blade, cutting speed and / or feed rate too high	Replace saw bladeReduce cutting speed and / or feed rate
Saw tooth tips overheated	Blunt or incorrect saw blade, cutting speed and / or feed rate too high	Replace saw bladeReduce cutting speed and / or feed rate

11 Optional accessories

• Rechargeable battery PowerTank 18 M 72 LiHD Order No. 094500
• Rechargeable battery PowerTank 18 M 72 LiHDX Order No. 094523
• Rechargeable battery PowerTank 18 M 99 LiHD Order No. 094503
• Rechargeable battery PowerTank 18 M 144 LiHD Order No. 094498
• Rechargeable battery PowerTank 18 M 144 LiHDX Order No. 094520
• Rechargeable power station APS M Order No. 094492
• Rechargeable power station APS M+ Order No. 094509
• Rechargeable PowerStation APS M+ - GB Order No. 094511

Further information on optional accessories can be found on our homepage: www.mafell.com

12 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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MAFELL AG

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