mafell ZSX Ec Carpenter’s Chain Saw Instruction Manual

mafell ZSX Ec Carpenter's Chain Saw Instruction Manual

WARNING
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.

EC Declaration of Conformity
We herewith confirm that the machine ZSX Ec 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

2 Product information

for machines with product no. 925501, 925502, 925503, 925520, 925521, 925522 or 925530

2.1 Manufacturer´s data

MAFELL AG, Beffendorfer Straße 4, D-78727 Oberndorf / Neckar, Phone +49 (0)7423/812-0, Fax +49 (0)7423/812-218, e-mail: mafell@mafell.de

2.2 Machine identification

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

2.3 Technical data

2.4 Emissions

The declared noise emission values have been measured in accordance with DIN EN 62841-1 and may be used for comparing the tool with another and also in a preliminary assessment of exposure.

⚠ Danger
The noise emissions during actual use of the power tool can differ from the declared values depending on the ways in which the tool is used especially what kind of workpiece is processed.
Always wear hearing protection, even when the power tool ist running idle in addition to the trigger time!

2.4.1 Noise emission specifications

Noise emission values determined according to EN 62841:

Idling Machining

Sound power level 111 dB (A) 108 dB (A)

Workplace-related emission value 100 dB (A) 97 dB (A)

2.4.2 Vibration specifications

The typically assessed acceleration is 3.2 m/s2.

2.5 Scope of supply

2.6 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:

– protective equipment above the base plate
– bottom deflection with guard plate
– special design of the saw chain
– riving knife/splitter
– large base plate and parallel stop
– handles
– index mechanism with lock and brake

2.7 Use according to intended purpose

The carpenter’s chain saw is exclusively suited for longitudinal and cross cutting of solid wood up to a maximum thickness of 400 mm (15 3/4 in.) exclusively using the special saw chain provided by

MAFELL, with the machine having to rest on the workpiece with its base plate 3 (Fig. 1). The machine may be operated by one person only. At the same time, the machine must be held and guided by its two handles 1 and 2 provided for that purpose.

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.

2.8 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 running saw chain below the base plate.
– Touching the standing saw chain below the base plate.
– Machine backlash if the blade gets stuck in the workpiece.
– Tearing of the saw chain.
– Ejection of timber cuttings.
– 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.
– Do not carry the machine by its cable and do not use the cable to pull the plug out of the socket outlet.
– Pay attention that the cable is protected against oil and heat and is not pulled across sharp edges.
– Damaged cables or plugs must be immediately replaced. Replacement may only be carried out by Mafell or an authorised MAFELL service workshop in order to avoid safety hazards.
– Avoid sharp bends in the cable. Especially when transporting and storing the machine, do not wind the cable around the machine.
– Always check before beginning work, whether the protection and work equipment is safely attached and not damaged. Damaged protection devices and parts must be repaired or replaced appropriately.
– Consider environmental influences. Do not expose the machine to rain and avoid working in a damp or wet environment as well as near to combustible liquids or gases.
– Store the device in a dry, locked place outside the reach of children.
Instructions on the use of personal protective equipment:
– Always wear ear protectors during work.
– Always where a dust mark during work.
– Always wear closely fitting work clothes (no shorts) and take off rings, wristbands, and watches.
Instructions on operation:
– Provide for an unobstructed and slip-proof location with adequate lighting.
– The power plug must be pulled before replacing tools, making adjustments and repairing malfunctions (this also comprises removing jammed splinters).
– Do not work on workpieces which are too small or too large for the capability of the machine.
– Whenever possible, secure the workpiece against slipping, e.g. with screw clamps.
– Only use original MAFELL saw chains. Commercial saw chains are not suitable for this machine. After every chain change, check the correct chain tension.
– The riving knife/splitter 4 (Fig. 1) including the guard plate for the bottom chain deflection 6 may not be removed.
– The machine is a one-man tool and may only be used for work during which the base plate 3 (Fig. 1) serves as work plate.
– Prior to carrying out any work, check whether the tank contains oil for the chain lubrication and whether the chain lubrication is working (see section 4.4).
– Keep a firm hold on the machine already before switching it on and support it. At the same time, rail and chain must stand unobstructed. Only begin cutting the workpiece when the saw chain has achieved its full speed. Pay attention to a secure footing.
– The switch may not be wedged in ON position.
– Never reach below the base plate or into the chip ejector during sawing.
– Never transport the machine with running saw chain and pay attention that, except for the workpiece, the running chain does not come in contact with adjacent objects.
– Never remove cover 12 (Fig. 1) covering the chain pinion with the machine running and only for a tool change and refit immediately afterwards.
– As the machine cannot be connected to an exhaustion, it may only be used to work outdoors or in sufficiently ventilated rooms.
– Once adopted, never change a cutting direction by force. The saw must be guided such that the pressure does not bring the chain to a stop.
– Examine the workpiece for foreign objects. Never attempt to cut into nails or other metal objects.
– Always lead the connecting cable away from the machine to the rear while sawing.
– Immediately pull the power plug in case of damaged or severed connecting cables.
– Match the feed speed during sawing to the material thickness. Feeding too fast results in an overload of the motor, rough saw cuts and faster blunting of the saw chain.
– Only remove the machine from the workpiece if the saw chain has come to a standstill. Thanks to the built-in brake, this happens very quickly.
– Do not operate the machine with bent or damaged riving knife.
– Ensure that the handles are free from chain oil.
– Never reach under the workpiece during operation.
– Keep the area under the workpiece free of obstacles. At the same time, pay attention to the machine’s large pivoting range.
– Note that the saw chain and the guide rails can be hot shortly after processing.
– Note that cuttings falling down when sawing large workpieces can cause injuries.
– Be particularly careful when sawing the last workpiece to be sawed. The machine’s supporting surface will be reduced. If necessary, clamp an additional workpiece to ensure the machine has a stable support.
Instructions on service and maintenance:
– Regular cleaning of the machine, in particular the setting mechanisms for tilting the guides for the parallel stop and the enclosure of the top and bottom chain deflection, constitutes an important safety factor. Pull the plug before starting this work.
– 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 during cleaning! There is risk of injury from touching the sharp teeth of the saw chain during cleaning. Wear protective gloves. Exercise caution during cleaning work.
– Risk of injury when changing the saw chain! There is a risk of injury from touching the sharp teeth of the saw chain when changing the saw chain. Wear protective gloves. Exercise caution when changing the saw chain.

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 Saw chain change

⚠ Danger It is imperative to pull the power plug before replacing the saw chain. Risk of injury even if the saw chain is standing still.
Proceed as follows to replace the saw chain:

• Unfasten cylinder head bolt 13 using combination screw driver 11 enclosed in the supply and fastened on cover 12 (Fig. 1) and fold down the cover.

• Open the spring-loaded bottom guard flap 15 (Fig. 10) downwards and fasten it with the cover in open position.

• Unscrew the hexagon socket head cap screw 18 (Fig. 2) and remove the Intermediate cover 19 including the oil tank.

• Unfasten the fastening screw 5 (Fig. 1) for the lower chain deflection protection and fold down the guard plate 6.

• Release the chain tension by turning the tensioning screw 20 (Fig. 3) to the left by means of combination screw driver 11.

• Pull off the guide rail 21 including the saw chain and chain wheel 22 to the front and remove the chain.

• Place a new or freshly sharpened saw chain onto the guide rail and the chain wheel. In the process, pay attention that the tooth cutting edges of the chain point in direction of the marking 24 for the direction of travel and that the chain fastening bolt 23 engages in the hole in the guide rail provided for that purpose. Using combination screw driver 11 (Fig. 7), twist the gear shaft such that chain wheel 22 with the fitted saw chain easily engages in the driving gear teeth.
  After installation of the saw chain set, immediately pull off combination screw driver 11.

• Slide open the intermediate cover 19 and slightly tighten the hexagon socket head cap screw 18. Using combination screw driver 11, turn the clamping screw 20 (Fig. 3) that can be reached through the hole in the intermediate cover clockwise until the correct chain tension has been achieved (see section 4.3).

• Tighten the hexagon socket head cap screw 18. Fold up the protection for the bottom chain deflection and tighten it with screw 5 (Fig. 1).

• Unlock the bottom guard flap 15 (Fig. 2). Fold up the cover 12 and tighten the cylinder head bolt 13. Fasten combination screw driver 11 in the brackets inside the cover.

If a new saw chain has been fitted, it must be run in in idling mode for approx. 2 to 3 minutes. Pay attention to adequate chain lubrication. After running-in, it may be necessary to correct the chain tension.

4.3 Chain tension

For a safe operation of the machine and for the life time of the entire chain set it is important that the correct chain tension is set. This must therefore be checked prior to start-up and once in a while during operation. The chain tension is set correctly if in a cold operating condition, the saw chain abuts on the guide rail and can be manually lifted by 3 to 4 mm (1/8 to 3/16 in.).
When heated to operating temperature, the saw chain elongates and starts to sag. If the elongation is that large that the chain links start to disengage from the guide at the rail, the saw chain must be pretensioner.

⚠ Danger
Pull the power plug during all service work.
Proceed as follows to retention the saw chain:

• Open the spring-loaded bottom guard flap 15 (Fig. 2) downwards. Using combination screw driver 11 fastened on cover 12 (Fig. 1), slightly release the hexagon socket head cap screw 18 (Fig. 2) through the bottom opening in cover 12 and screw 5 (Fig. 1).
• Adjust the chain tensioning screw 20 through the top opening in the cover (see Fig. 1) using combination screw driver 11. Turning clockwise means increasing and turning anti-clockwise means decreasing the chain tension.
• Tighten the hexagon socket head cap screw 18. Fold up the protection for the bottom chain deflection and tighten it with screw 5 (Fig. 1).

If the saw chain is pretensioner after it has heated up, it is absolutely necessary to slacken it again once sawing has been completed. Failure to do so would cause very high shrinkage stresses due to the saw chain contracting when cooling down to ambient temperature, in particular if very low outside temperatures are prevailing.
Until it has elongated, a new saw chain must be pretensioner more frequently than a saw chain that has already been used for a longer period of time.

4.4 Chain lubrication

Correct lubrication of the saw chain is of major importance for its life time. A dry running chain will quickly damage the entire chain set irreparably. Lubrication is adequate if a trail of oil is visible between saw chain and guide rail.
It is therefore important to check the chain lubrication function prior to the start of work and to check the oil level in the lubricant tank. It may not drop below the marking placed in cover 12 (Fig. 1) next to inspection window 14. Only use biodegradable oil for the refill.

The oil tank filling quantity amounts to approx. 0.3 litres.

⚠ Danger
Pull out the mains plug before starting to adjust the chain lubrication. If any oil should get into your eyes during refilling, immediately rinse them with a copious amount of water. Spilled oil must be absorbed with commercial oil binders. The handles must be free from oil!
The flow rate of the built-in oil pump can be adjusted. A normal dosing rate has been set at the factory, which can be verified by the fact that an oil trace is visible between saw chain and guide rail. However, if necessary, the dosing rate can be changed. Proceed as follows:

• Unfasten cylinder head bolt 13 using combination screw driver 11 enclosed in the supply and fastened on cover 12 (Fig. 1) and fold down the cover.
• Open the spring-loaded bottom guard flap 15 (Fig. 2) downwards and fasten it with the cover in open position.
• Unscrew the hexagon socket head cap screw 18 (Fig. 2) and remove the Intermediate cover 19 including the oil tank.
• Dosing screw 25 (Fig. 4) that is now accessible at the rear of the intermediate cover can be used to adjust the oil pump’s flow rate. Turning the screw clockwise increases the flow rate, turning it anti-clockwise decreases the flow rate.
• Refit the intermediate cover 19 (Fig. 2) and tighten it with hexagon socket head cap screw 18.
• Unlock the bottom guard flap 15 (Fig. 2). Fold up the cover 12 (Fig. 1) and tighten the cylinder head bolt 13. Fasten combination screw driver 11 in the brackets inside the cover.
• Whether the flow rate now meets the requirements can now be checked by briefly switching on the machine.

4.5 Setting the parallel stop

The parallel stop 7 (Fig. 1) is used to execute parallel cuts along the outside edge of the workpiece from a cutting width of 175 mm (6 57/64 in.). For this purpose, the narrow edge of the stop must point downwards.
The stop can be used on both sides of the machine.
To adjust the cutting width or to use it on the other side of the machine, the two wing screws 8 (Fig. 1) are unfastened, the parallel stop is moved accordingly and then the wing screws are retightened well.
The base plate is equipped with reading edges at all four slide-in positions on which the markings applied to the guide rods of the parallel stop can be read off. In this manner, the parallel stop can be set exactly parallel to the chain set.
When using the parallel stop on the left-hand side of the machine, the cutting width is the direct measurement between the guide surface of the limit stop and the tracing edge 26 (Fig. 6). This measurement is the same for all cutting angles! If the parallel stop is used on the right-hand side of the machine, the chain width must still be deducted from this measure (6.8 mm for a vertical cut). However, in this case it is recommended to determine the correct setting by executing a trial cut. If the right-hand side of the chain is used to saw at the marking, tracing edges 27 graduated according to cutting angle apply (Fig. 6).

4.6 Setting for angle cuts (bevel and jack rafter cuts)

⚠ Danger!
Risk of injury from ejected saw cuttings
Saw cuttings can be hurled against the base plate or in the direction of the sawing process. There is risk of injury! Before starting to saw, pay attention that there are no persons or objects in the surroundings of the saw. Remove any saw cuttings slipping off. Switch off the machine to do so. Wait until the saw chain is idle.

In order to carry out bevel cuts and jack rafter cuts, the chain guide rail can be swivelled in both directions up to 60°. To do so, the machine is placed onto a corresponding support such that the chain guide rail is free moving. After unfastening handle 16 (Fig. 1) and deactivating locking lever by pulling and twisting handle 9, the machine can be swivelled. The cutting angle can be read of the angle scale 17.
If the locking lever is activated, this facilitates setting the 0° and 45°- positions.
Depending on the set cutting angle, the maximum cutting depths amount to:

After setting the cutting angle, retighten handle 16.

4.7 Installing the dust extraction adapter

The ZSX-AA dust extraction adapter is installed without tools.

• Unscrew the knurled screw 31 (Fig. 12) of the ZSX-AA dust extraction adapter completely to the stop.
• When fitting the ZSX-AA, first of all secure it on the existing screw of the ZSX discharge flap 29.
• Place the ZSX-AA completely onto the machine.
• Now tighten the knurled screw 31 hand-tight.

The ZSX-AA dust extraction adapter can only be used in conjunction with the dust extraction hose Ø49 mm (order No. 093682) and dust extractor S 35 M (Order No. 919701) or high-capacity extractor S200 (Order No. 206869).

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

⚠ Danger Before switching on the machine, pay attention that the guide rail and the saw chain are unobstructed. The workspace underneath the workpiece must be free of obstacles. Lead the connecting cable away to the rear. Hold the machine with both hands by the handles provided for that purpose.

• Switching on: First unlock the switch-on lock by pressing the locking lever 10.1 (Fig. 1) to the front. Then actuate the control lever 10. As this is a switch without locking device, the machine will only run for as long as this switch is pressed.
  The carpenter’s chain saw ZSX Ec is equipped with an electronic speed control. The speed is continuously variable between 3000 and 3600 rpm. The required speed is set with the aid of the setting wheel 30 (Fig. 1).
  When using a carbide or fine-cut chain, it is recommended to set the speed to the lowest value. When using a cross cut chain set it to the highest value.
  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.

• Switching off: To switch off, release the switch trigger 10. The switch-on lock automatically takes effect again and secures the carpenter’s chain saw against accidental switch-on.
  On switching off the machine, the automatic brake takes effect simultaneously. This shortens the slowing time of the saw chain to approx. 1 second.

5.3 Work instructions

The handling and layout of the carpenter’s chain saw ZSX Ec corresponds to a portable circular saw. The riving knife/splitter 4 prevents the saw chain from jamming and the safeguard of the bottom chain deflection a turning up of the machine. It is particularly suited for cross cuts requiring a large cutting depth, in particular also for joining laminated timber.

Before switching on, place the machine with its base plate 3 such onto the workpiece that there is not yet any contact between saw chain and workpiece. Hold the machine by both handles 1 and 2 and after switching on, slide evenly forwards without canting. Therefore, if possible, always guide the machine with the parallel stop either along the workpiece edge or along a guide rail that is available as special accessory (see section 4.5). The use of a guide rail achieves a clearly higher cut quality.

5.4 Large cutting lengths

For large cutting lengths (e.g. several beams in a row) the guide rail can be tilted to the rear by 10° (see Fig. 5). This makes it easier to guide the machine straight ahead, in particular at the transition from one workpiece to the next.

⚠ Danger Pull the power plug during all service work.
For tilting, first of all the two set screws 28 (Fig. 5) are unfastened and the chain guide rail is tilted up to the limit stop in the direction of the rear handle. Then tighten the set screws again.

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.

6.1 Machine

The machine must be regularly cleaned off deposited dust. When doing so, you should clean the ventilation openings on the motor with a vacuum cleaner. Only use our special grease, order No. 049040 (1 kg tin) for all greasing points. Only use our special grease, order no. 049065 (400 g tin) for gear lubrication. The chain sets used on the machine should be regularly deracinated, as clean tools improve the quality of the cut. Deracination is carried out by soaking the chain set in petroleum or a commercial deracination agent for 24 hours.

6.2 Guide rail of the chain set

This guide rail must be maintained regularly. This includes lubricating the chain deflection wheel and deburring the rail.

Lubricating the carbide guide rail – see Fig. 8

• Dismantle chain set (see section 4.2).

• Clean lubrication hole.

• Place guide rail onto a flat surface.

• Press the mouthpiece of the grease gun tightly into the lubrication hole and press until grease emerges at the deflection. Use a good, acid-free bearing grease for this purpose.

• Refit the chain set (see section 4.2).
  Deburring – see Fig. 9

• Dismantle chain set (see section 4.2).

• Remove chain from the guide rail.

• Remove the burr using a flat file as shown in Fig. 9.

• Replace the chain and refit the chain set (see section 4.2).

6.3 Chain wheel

The stress on chain wheel 22 (Fig. 3) is particularly high. If it exhibits extremely visible grooves at the individual teeth (approx. 0.5 mm / 1/64 in.) it must be replaced without fail. MAFELL recommends to have this work carried out by an authorised customer service shop.

6.4 General sharpening information

Just as important as quality and care of the machine are quality and care of the saw chain, guide rail and chain pinion. If the care of one of these «partners», which are acting jointly during sawing, is neglected, the consequences are frequently:

– Wear or destruction of other partners
– Lacking cutting performance
– Bad surface
– A possible safety risk
Nails or adhering sand will damage the saw chain. They must be removed from the cut surface.
Saw chains for: ZSX Ec (Item No. 006955, 006968, 006971, 006972, 006974)
These chains can only be reground at MAFELL via your appointed dealer.

6.5 Transport and storage

⚠ Danger! Risk of injury due to improper transport or storage Bystanders can be injured by the machine due to improper transport or storage For transport and storage, place the machine onto the base plate so that the saw chain is exposed at the bottom. It is recommended to use the Mafell transport cart for transport and storage (see Chapter 8, “Special accessories”).
Clean the machine thoroughly if the machine is not used for a longer period of time. Spray blank metal parts with a rust-proofing agent.

7 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.

8 Optional accessories

9 Exploded drawing and spare parts list

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

WARRANTY
Upon presentation of the warranty document (original invoice), we will carry out all repairs free of charge in accordance with the applicable warranty provisions, processing and mounting faults free of charge on presentation of this properly filled-in Guarantee Certificate and your original receipt. This is not valid for consumables and wearing parts. For this purpose, the machine or the appliance is to be forwarded freight paid to our plant or to an authorized MAFELL repair service. Refrain from trying to carry out the repairs yourself as otherwise your warranty claim will become extinct. We do not accept any liability for any damage resulting from improper handling or normal wear.

MAFELL AG
Beffendorfer Straße 4, D-78727 Oberndorf / Neckar
Telefon +49 (0)7423/812-0
Fax +49 (0)7423/812-218
Internet: www.mafell.de
E-Mail: mafell@mafell.de

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