mafell MT55cc Plunge Cut Saw Instruction Manual

**mafell MT55cc Plunge Cut Saw

**

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 MT 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

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.

Product information

for machines with product no. 917602, 917603, 917628, 917630, 917631, 917632, 917633, 917634, 917635, 917636, 917637 or 917638

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

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.

Technical data

Universal motor, radio and TV interference suppressed 230 V~, 50 Hz 110 V~, 50 Hz 120 V~, 60 Hz
Power input (nominal load) 1400 W
Current at nominal load 7,0 A 13,5 A 13,5 A
Saw blade speed during idling 3600 – 6250 rpm
Saw blade speed at normal load 3600 – 6250 rpm
Cutting depth 57 mm (2 1/4 in.)
Swivelling saw unit -1°/ 0°- 48°
Saw blade diameter max/min 162/149 mm (6 3/8 / 5 7/8 in.)
Saw blade body thickness 1.2 mm (3/64 in.)
Tool cutting width 1.8 mm (5/64 in.)
Saw blade mounting hole 20 mm
Hose connector diameter 35 mm (1 3/8 in.)
Weight without mains cable, without parallel guide fence 4,5 kg (9.9 lbs)
Dimensions (W x L x H) 228 x 365 x 220 mm (9 x 14 3/8 x 8 5/8 in.)

Emissions
The declared noise emission values have been measured in accordance with DIN EN 62841-1 and DIN 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 ist running idle in addition to the trigger time!

Noise emission specifications

Noise emission values determined according to EN 62841:
Sound pressure level LPA = 93 dB (A)
Uncertainty KPA = 3 dB (A)
Sound power level LWA = 104 dB (A)
Uncertainty KWA = 3 dB (A)

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

Vibration specifications
The typical hand-arm vibration according to EN 62841 is less than 2.5 m/s2.

Scope of supply
Portable circular saw MT 55 cc complete with:

1 carbide-tipped circular saw blade Ø 162 mm (6 3/8 in.), 48 teeth
1 parallel guide fence (not on models MidiMAX)
1 service tool in bracket on the machine
1 carrying case
1 operating manual
1 folder “Safety Instructions”
1 position indicator MT-PA for Item No. 917603, 917631, 917633, 917635, 917637, 917658

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:

• Saw guard
• Large base plate
• Handles
• Index mechanism and brake
• Hose connector

Use according to intended purpose
The plunge cut 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.
The use of wood fibre insulation materials is also possible.
Only use the saw blades approved by Mafell in accordance with EN 847-1 in the specified ø-range.
In conjunction with the diamond saw blade you can also cut fibre cement board.
Any other use than described above is not permissible.
The manufacturer cannot be held liable for any damage arising from such other use.
In order to use the machine as intended, comply with the operating, maintenance, and repair instructions specified by Mafell.

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 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.

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. Replacement may only be carried out by Mafell or an authorised MAFELL service workshop in order to avoid safety hazards.
• Avoid sharp bends in the cable. Especially when transporting and storing the machine, do not wind the cable around the machine.

Do not use:

• Cracked and misshapen saw blades.
• Saw blades made of high speed steel (HSS saw blades).
• Blunt saw blades as they impose an excessive load on the motor.
• 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:

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 ten to sag under their own weight. Supports must be placed under the panel on both sides, near the line of cut and near the edge of the panel.

• Do not use dull or damaged blades.
  Unsharpened or improperly set blades produce narrow kerf causing excessive friction, blade binding and kickback.

• Blade depth and bevel adjusting locking levers must be tight and secure before making the cut.
  If blade adjustment shifts while cutting, it may cause binding and kickback..

• Use extra caution when sawing into existing walls or other blind areas. The protruding blade may cut objects that can cause kickback.

Lower guard function

• Check the lower guard for proper closing before each use. Do not operate the saw if the lower guard does not move freely and close instantly.
  Never clamp or tie the lower guard into the open position. If the saw is accidentally dropped, the lower guard may be bent. Raise the lower guard with the retracting handle and make sure it moves freely and does not touch the blade or any other part, in all angles and depths of cut.

• Check the operation of the lower guard spring.
  If the guard and the spring are not operating properly, they must be serviced before use.
  Lower guard may operate sluggishly due to damaged parts, gummy deposits, or a build-up of debris.

• The lower guard may be retracted manually only for special cuts such as “plunge cuts” and “compound cuts”. Raise the lower guard by the retracting handle and as soon as the blade enters the material, the lower guard must be released. For all other sawing, the lower guard should operate automatically.

• Always observe that the lower guard is covering the blade before placing the saw down on bench or floor. An unprotected, coasting blade will cause the saw to walk backwards, cutting whatever is in its path. Be aware of the time it takes for the blade to stop after switch is released.

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.

Setting / Adjustment

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

Chip extraction
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 1 (Fig. 1) is 35 mm (1 3/8 in.).

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 or hard wood:

• TCT circular saw blade Ø 160 x 1.8 x 20 mm (6 ¼ x 5/64 in. x 20 mm), 32 teeth

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

• TCT circular saw blade Ø 160 x 1.8 x 20 mm (6 ¼ x 5/64 in. x 20 mm), 16 teeth

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

• TCT circular saw blade Ø 162 x 1.8 x 20 mm (6 3/8 x 5/64 in. x 20 mm), 48 teeth

For cuts in fibre cement board:

• Diamond saw blade Ø 160 x 3.0 x 20 mm (6 ¼ x 1/8 in. x 20 mm), 4 teeth

Replacing the saw blade

Danger
Pull the power plug during all service work.

• So as to fold down the saw guard cover 23 (Fig.3) on the side, actuate push-button 2 (Fig. 4) and pull locking lever 3 upwards. Pulling the locking lever automatically locks the saw shaft and locks the gearshift lever.
  
  

• Using the Allen key 4 (brackets Fig. 2), unfasten the flange screw 5 (Fig. 3) counter clockwise. Remove the screw and the front clamping flange 6.
  

• You can now remove the saw blade by lifting it to the front.

• 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.

• Close the saw guard cover. To this end, close the cover and press the locking lever 3 (Fig.3) downwards.

Installation

Operation

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”.

Switching on and off

• Switching on: First of all, unlock the switch-on lock by pressing the locking lever 7 (Fig. 4). Then, keeping the locking lever depressed, activate the gearshift lever 8.

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

With the setting wheel 9 (Fig. 2) you can steplessly adjust the saw speed between 3600 and 6250 rpm.

Material groups

1. PVC, Plexi, PA
   – Level: 1 – 6

2. Hardwood, softwood, plywood
   – Level: 3 – 6

3. Coated panel materials
   – Level: 4 – 6

4. Fibre cement board
   – Level: 3 – 5

• Switching off: To switch off, release the switch trigger 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.

Cutting depth adjustment
The cutting depth is continuously variable between 0 and 57 mm (0 to 2 ¼ in.), graduated in 1 mm steps.

Proceed as follows:

• Adjust the indicator 10 (Fig. 4) by turning it into the top or bottom position, depending on whether you are working with or without the guide rail.
• Set the cutting depth with the depth stop 11 according to the scale. The limit stop has a 1 mm latching mechanism.
• In order to set intermediate measurements, you can turn the cylinder screw 12 (Fig. 4) with the
  Allen key 4 (retaining bracket Fig. 2). One turn corresponds to 1 mm change in cutting depth.
  Always set the cutting depth approx. 2 to 5 mm (5/64 to 13/64 in.) larger than the material thickness to be cut.

Setting for bevel cuts
For bevel cuts, the saw unit can be set to any angle between 0 °and 45°.

• Unfasten the wing screw 13 (Fig. 4).
• Adjust the angle according to the scale on the segment for tilting.
• Afterwards, tighten the wing screw 13.

In addition, the machine can be tilted to -1° or 48°.

• To tilt to -1°, pull the slide bar 14 (Fig. 4)backwards in the direction of the arrow and hold on to it.
• Tilt the machine to -1°.
• To tilt the machine to 48°, press the limit stop 15 (Fig. 3) downwards.
• Tilt the machine to 48°.
• 45° and 0°- limit stop are automatically reset after they have been traversed.

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. When using the guide rail (special accessories) you must fasten the limit stop available as special accessory on the guide rail. Keep a firm hold on the machine handle during plunging and push the saw lightly forward!

• The markings 16 (Fig. 1) on the bottom saw guard and on the slide bar serve as orientation for the cutting area of the completely plunged saw blade if the guide rail (special accessories) is used.

Sawing according to tracings
The figure is equipped with a tracked score indicator 17 (Fig. 1) both for straight cuts and for bevel cuts. This tracing edge corresponds to the saw blade’s inside.

• Secure the workpiece against shifting and arrange the workpiece supports such that the saw blade is running freely underneath the workpiece.

• Hold the machine by its handle and place the front part of its base plate onto the workpiece.

• Switch on the plunge cut saw (see Chapter 5.2).
  Plunge to the set cutting depth and slide the machine evenly forward in the direction of the cut.

• When the cut is completed, switch off the saw by releasing the gearshift lever 8 (Fig. 4). Tilt the saw unit back into the top locked position.

Sawing with parallel guide fence
When making parallel cuts, the parallel guide fence 18 (Fig. 1) serves to saw parallel to an already existing edge. The guide fence can be attached to the left or right of the machine. The cutting range on the righthand side amounts to approx. 140 mm (5 ½ in.) and on the left-hand side to approx. 295 mm (11 5/8 in.).

• Once you have unfastened the wing screws you can adjust the cutting width 19 (Fig. 2) by moving the guide fence 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 plunge cut saw. Now the machine can be guided along a lath that is fastened on the workpiece.

Scoring with the guide rail (special accessories)
In case of panel materials you can achieve a clean cut if you score.
Use a suitable saw blade (see Chapter 4.3).

To avoid the surface from tearing out, proceed as follows:

• Fasten the guide rail on the workpiece.
• Tilt the locking lever 20 (Fig. 2) clockwise up to the limit stop. The scoring depth is now set to approx. 3 mm (1/8 in.).
• Place the machine with the guide groove onto the guide rail.
• Set the cutting depth – take into account the guide rail thickness (see Chapter 5.3).
• Score the board. Tilt the locking lever 20 (Fig. 2) counter clockwise up to the limit stop.
• Plunge to the preset cutting depth and saw the full board thickness.

Working with the diamond saw blade in fibre cement board (special accessories)

Proceed as follows:

• Use a suitable saw blade (see Chapter 4.3).
• Exchange the saw blade (see Chapter 4.4).

The diamond saw blade was developed for fibre cement board.
The diamond-fitted teeth are more delicate than the teeth of the HM saw blade. This is why you are working with a guide rail.

Working with guide rails

• To achieve more accurate guidance, set the guide clearance with the two setting wheels 21 (Fig.2 and 4).

The plunge cut saw can be used to work with the guide rails that are available as special accessories.

In addition, it is possible to use some rails that are freely available on the market.

• To do so, unscrew the screws and remove the insert 24 (Fig.2).

Working with the position indicator MT-PA
For pictograms in this regard see page 4.

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.

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.

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.

power supply checked by an electrician
Mains fuse defective| Have fuse replaced by an electrician
Carbon brushes worn| Take the machine to a MAFELL customer service shop
Machine stops while cutting is in process| Mains failure| Have mains-side pre- fuses checked by an electrician
Machine overloaded| Reduce feed speed or allow machine to cool down
Carbon brushes worn| Take the machine to a MAFELL customer service shop
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 (for example due to free-hand 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 operation without exhaustion| Connect to an external exhaustion, e.g. portable dust extractor

Optional accessories

• Saw blade-TCT ø 160 x 1.8 x 20 mm (6 1/4 x 5/64 in. x 20 mm), 16 teeth (longitudinal cut) Order No. 092539

• Saw blade – TCT ø 160 x 1.8 x 20 mm (6 1/4 x 5/64 in. x 20 mm), 24 teeth (longitudinal and crosscuts) Order No. 092533

• Saw blade – TCT ø 160 x 1.8 x 20 mm (6 1/4 x 5/64 in. x 20 mm), 32 teeth (longitudinal and cross cuts) Order No. 092552

• Saw blade – TCT ø 160 x 1.8 x 20 mm (6 1/4 x 5/64 in. x 20 mm), 56 teeth (cross cut) Order No. 092553

• Saw blade – TCT ø 162 x 1.8 x 20 mm (6 3/8 x 5/64 in. x 20 mm), 48 teeth (cross cut) Order No. 092584

• Saw blade- TCT ø 160 x 1.8 x 20 mm (6 1/4 x 5/64 in. x 20 mm), 48 teeth FZ/TR for sawing Trespa (laminated sheets) Order No. 092569

• Saw blade DIA ø 160 x 3.0 x 20 mm (6 1/4 x 1/8 in. x 20 mm), 4 teeth Order No. 092474

• Guide rail F 80, 800 mm (2.6 ft) long Order No. 204380

• Guide rail F 110, 1100 mm (3.6 ft) long Order No. 204381

• Guide rail F 160, 1600 mm (5.25 ft) long Order No. 204365

• Guide rail F 210, 2100 mm (6.9 ft) long Order No. 204382

• Guide rail F 310, 3100 mm (10.2 ft) long Order No. 204383

• Sliding bevel segment F-WA Order No. 205357

• Accessories for guide rail:

  • Screw clamp F-SZ100MM (2 pcs.) Order No. 205399
  • Connecting piece F-VS Order No. 204363
  • Rail bag 160 Order No. 204626

• Rail bag kit F80/160 consisting of: F80 + F160 + connecting piece + 2 screw clamps + rail bag Order No. 204748

• 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. 204749

• Rail bag kit F160/160 consisting of: 2 x F160 + connecting piece + 2 screw clamps + rail bag Order No. 204805

• acklash stop F-RS Order No. 202867

• Position indicator MT-PA Order No. 205398

• Parallel stop, cpl. Order No. 203214

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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