mafell MF26cc Groove Cutting Machine Instruction Manual

mafell MF26cc Groove Cutting Machine

Product Information

The MF 26 cc groove-cutting machine is a powerful and versatile tool that can be used for cutting grooves in various materials. The  machine is manufactured by an undisclosed company and comes with arange of safety features to ensure safe usage. The machine has a compact design and is easy to operate, making it suitable for both novice and experienced users.

Specifications

• Model: MF 26 cc
• Product   code: 170278.0517/g
• Type: Groove-cutting machine
• Voltage: N/A
• Power consumption: N/A

Included in the Box

The package includes the groove-cutting machine, safety instructions and directions, and a set of tools for assembly and maintenance.

Safety Features

The machine is equipped with various safety features, such as:

• Warning labels and instructions for safe usage
• Sturdy construction to prevent tipping over
• Specialized tools to prevent accidental contact with blades

Product Usage Instructions

Before using the MF 26 cc groove-cutting machine, it is essential to read and understand all safety instructions and directions provided in the user manual. Failure to comply with the safety instructions and directions can cause electric shock, fire, and/or serious injuries.

Assembly Instructions

1. Secure the machine against tipping over before assembly.
2. Select the appropriate tool for the task at hand.
3. Attach the tool to the groove-cutting machine according to the instructions provided.
4. Adjust the blade depth and width to the desired dimensions.

Operation Instructions

1. Connect the machine to a power source as per instructions provided.
2. Switch on the machine and wait for it to reach full speed.
3. Position the machine on the material to be grooved.
4. Slowly move the machine along the surface of the material, following the desired groove pattern.
5. Switch off the machine and disconnect it from the power source after use.

It is essential to wear appropriate personal protective equipment (PPE), such as safety glasses, gloves, and ear protection, when operating the machine. It is also crucial to keep the machine clean and well-maintained to ensure optimal performance and longevity.

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 MF26cc 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

Product information

for machines with item No. 917801, 917802, 917804, 917820, 917821, 917822, 917823, 917825, 917840, 917841, 917842, 917843, 917845, 917880, 917881, 917882, 917883, 917885 or 987420

Manufacturer´s data
MAFELL AG, Beffendorfer Straße 4, D-78727 Oberndorf / Neckar, Phone +49 (0)7423/812-0, Fax +49 (0)7423/812-218

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

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
  • 10,0 A
  • 10,0 A
• Tool speed while idling 3600 – 6250 rpm
• Tool speed at normal load 3600 – 6250 rpm
• Cutting depth 0 – 26 mm (0 – 1 1/32 in.)
• Tool diameter max. 122 mm (4 51/64 in.)
• Tool mounting hole 20 mm
• Hose connector diameter 35 mm (1 3/8 in.)
• Weight without mains cable, without parallel guide fence 5.0 – 6.6 kg (11 – 14.5 lbs)
• Dimensions (W x L x H) 250 x 330 x 215 mm (9 27/32 x 13 x 8 15/32 in.)

Noise emission specifications

• Noise emission values determined according to EN 60745-1 and EN 60745-2-5:
  • Sound power level: 104 dB (A)
  • Workplace-related emission value: 93 dB (A)
• The noise level measurement was carried out with a saw blade, adjustable groove cutter, slitting unit, plasterboard and aluminium compound milling cutter supplied with the machine as 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.

Vibration specifications
The typical hand-arm vibration is 3.6 m/s2.

Scope of supply
Groove-cutting machine MF26cc complete with:

• 1 milling tool
• 1 saw blade (for MAX aluminium with 40 teeth, for MAX construction, GF and KSS wood with 24 teeth)
• 2 position indicators
• 1 parallel stop cpl.
• 2 operating tools
• 1 hose connector
• 1 chip deflector (only for model MAX aluminium)
• 1 carrying case (for models 917801, 917820, 917821, 917822, 917823, 917825, 917802, 917840, 917841, 917842, 917843, 917845, 987420)
• 1 transport case (for models 917804, 917880, 917881, 917882, 917883, 917885)
• 1 operating manual
• 1 folder “Safety Instructions”

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
•  Index mechanism and brake
• Hose connector

Use according to intended purpose
The groove-cutting machine is exclusively suited for longitudinal and cross cutting as well as for milling solid wood, panel materials such as chip board, coreboard, MDF board, gypsum plasterboard, aluminium compound panels and laminate panels.
Special use of the tools:

• The saw blade is exclusively suited for processing wood, plaster board panels, aluminium compound and laminate panels.
• The slitting unit (special accessories) is exclusively suited for processing wood and plaster board panels.
• The adjustable groove cutter is exclusively suited for machining wood.
• The plasterboard milling cutter is exclusively suited for processing wood and plaster board panels.
• The aluminium compound milling cutter is exclusively suited for machining aluminium compound panels.
• Only use the approved tools. Our tools are manufactured 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.
• To use the machine as intended, comply with the operating, maintenance and servicing conditions prescribed 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 will always remain.

• Touching the part of the saw blade that protrudes below the workpiece when cutting.
• Touching of turning parts from the side: Tool, clamping flange and flange screw.
• Machine backlash if the blade gets stuck in the workpiece.
•  Breakage and hurling out of the tool or parts of the tool.
• 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 hazardous dusts during longer lasting 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.
• 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 tools or tools that have changed their shape.
• Tools made of high speed steel (HSS tools).
• Blunt tools due to the excessive engine load.
• Tools that are not suitable for the tool speed during idling.

Instructions on the use of personal protective equipment:

• Always wear ear protectors during work.
• Always where a dust mark during work.
• Wear protective goggles during all work.

Instructions on operation:

• Keep your hands away from the cutting range and the tool. 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.
• When sawing with connected guide rail, the machine may only be removed from the workpiece when it is in home position and the retractable saw guard is closed..
• 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 tools of the correct size and with matching mounting hole (e.g. star-shaped or round).
• Never use damaged or incorrect tool washers or screws.
• Hold the machine 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 tool, never bring the tool in line with your body.
• Release the on/off switch if the tool is stuck or machining is interrupted for another reason. Keep the machine steady in the material until the tool has come to a complete standstill. Never try to remove the machine from the workpiece or pull it backwards as long as the tool is moving or could recoil.
• If you want to restart a tool that is stuck in the workpiece, centre the tool in the tool gap and check whether the teeth of the tool have got jammed in the workpiece.
• Support large plates to reduce the risk of a backlash caused by a jammed tool.
• Do not use any blunt or damaged tools.
•  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 saw guard is closing properly. Do not use the groove-cutting machine if the saw guard is unable to move freely and does not close immediately. Never clamp or tie down the saw guard in an open position.
• Check the state and function of the spring for the saw guard. Have the machine serviced prior to use if saw guard and spring do not work properly.
•  When carrying out plunge cuts, always secure the base plate of the machine against dislocation to the rear.
• Do not place the groove-cutting machine onto the workbench or floor without the saw guard covering the tool.
• Examine the workpiece for foreign objects. Do not saw or mill into steel parts.

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
Danger
Substances that are harmful to health must be taken up with an Msuction 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 1 (Fig. 1) is 35 mm (1 3/8 in.).

Cut quality
Use a sharp tool to achieve a good cut quality. Select a tool from the list in chapter 4.5 according to the material.

Secure machine against tilting
The cover of the groove-cutting machine is equipped with a glider as support against tilting. The glider must be turned for the respective application (with or without rail).

• Unscrew the fastening screw 27 (Fig. 1) using
  the Allen key 4 (Fig. 2).

•  Rotate the glider 28 (Fig. 1) around the fastening screw until the printed diagram on the glider (right) corresponds to the desired application (with or without rail). (Adjusting screws 26 (Fig. 1), which can be adjusted with the Allen key 4 (Fig. 2) are located at the bottom / top side of the glider for fine adjustment of the glider).

• Retighten the fastening screw 27 (Fig. 1).

Selection of tools

•  Saw blade-TCT Ø 120 x 1.8 x 20 mm (4 47/64 x 5/64 in. x 20 mm), 12 teeth
•  Saw blade-TCT Ø 120 x 1.8 x 20 mm (4 47/64 x 5/64 in. x 20 mm), 24 teeth
• Saw blade-TCT Ø 120 x 1.8 x 20 mm (4 47/64 x 5/64 in. x 20 mm), 40 teeth
•  Saw blade-TCT Ø 120 x 1.2 x 20 mm (4 47/64 x 3/64 in. x 20 mm), 40 teeth
• Slitting unit MF-SE3
• Adjustable groove cutter MF-VN25
• Plasterboard milling cutter MF-GF90/15
• Aluminium compound milling cutter MF-AF90 See also the table in chapter 9.

Tool change to saw blade, plasterboard milling cutter or aluminium compound milling cutter.
Danger:  Pull the power plug during all service work.
The chip deflector must be unscrewed prior to a tool change.

• Using the Allen key 4 (bracket Fig. 2), unscrew the countersunk screw with chip deflector 44 (Fig. 11).
•  To change the tools, place the machine with the marking 17 (Fig. 1) or splinter guard 38 (Fig. 4) on the edge of a support surface so that the cover can tilt across the edge when it is opened.
• To fold the saw guard cover 23 (Fig.4) down on the side, press push-button 2 (Fig. 5). With depressed push-button, pull locking lever 3 upwards. Pulling the locking lever automatically locates the shaft in position and locks the gearshift lever 8 (Fig. 5).
• Using the Allen key 4 (brackets Fig. 2), release the flange screw 5 (Fig. 4) counter clockwise. Pull off the slitting unit or adjustable groove cutter to the front.
•  Push the rear flange 29 (Fig. 8) onto the shaft (if not present).
• The clamping flanges must be free of adhering parts.
• Place the saw blade, the plasterboard milling cutter or the aluminium compound milling cutter onto the rear flange 29 (Fig. 8).
• When fitting the tool, pay attention to the sense of rotation (see direction of arrow on the casing and on the cover).
• Push the clamping flange and flange screw onto the tool.
•  Tighten the flange screw by turning it clockwise with the Allen key.
• Close the saw guard cover. To this end, close the cover and press the locking lever 3 (Fig. 5) downwards.
• The chip deflector must always be fitted when milling aluminium compound panels.

Tool change to slitting unit or adjustable groove cutter
Danger Pull the power plug during all service work.
The chip deflector must be unscrewed prior to a tool change.

•  To change the tools, place the machine with the marking 17 (Fig. 1) or splinter guard 38 (Fig. 4) on the edge of a support surface so that the cover can tilt across the edge when it is opened.
•  To fold the saw guard cover 23 (Fig.4) down on the side, press push-button 2 (Fig. 5). With depressed push-button, pull locking lever 3 upwards. Pulling the locking lever automatically locates the shaft in position and locks the gearshift lever 8 (Fig. 5).
• Using the Allen key 4 (brackets Fig. 2) release the flange screw 5 (Fig. 4) counter clockwise.
• Remove the flange 6 (Fig. 4) and the flange screw 5 (Fig. 4).
• Remove the rear flange 29 (Fig. 8) (if present).
• Push the slitting unit or adjustable groove cutter onto the shaft.
• Tighten the flange screw 5 (Fig. 4) by turning it clockwise with the Allen key.
• Close the saw guard cover. To this end, close the cover and press the locking lever 3 (Fig.5) downwards.

Setting the milling width or assembly of the adjustable groove cutter
The adjustable groove cutter 30 (Fig. 9) is a reversible knife adjustable groove cutter, which can be adjusted to milling widths between 15.4 and 25.0 mm (39/64 – 63/64 in.). Spacers in the following thickness are included with the adjustable groove cutter: 5 / 2 /1 / 0.5 (2x) / 0.3 (2x) / 0.1 (approx. 13/64, 5/64, 3/64, 1/32 – 2x, 1/64 – 2x, 1/128 in.). With these you can create interim widths in 0.1 – 0.2 mm (0.004 – 0.008 in.) steps.
Proceed as follows:

• First compile the required adjustable groove cutter width with the enclosed spacers (the adjustable groove cutter without spacers has a groove width of 15.4 mm (39/64 in.)).
• To assemble the individual parts of the adjustable groove cutter, first the spacers that are not required are pushed onto the front flange 31 (Fig. 9). Attention must be paid that the largest spacer thickness is always the first to rest on the clamping flange.
• Afterwards, first place the front part of the adjustable groove cutter (the side with the lettering) onto the flange.
• Then place the required spacers onto the flange.
• Fit the rear part of the adjustable groove cutter onto the flange and press the entire unit together (possibly while twisting it slightly) until the front flange engages with the rear flange.
  The adjustment range specified on the adjustable groove cutter may on no account be exceeded. Ensure that all the enclosed spacers are fitted at all times.

Assembly of the slitting unit

• Take the rear mounting of the slitting unit (star-shaped opening in the bore) with the short diameter into your left hand.
• Push the saw blade onto the mounting diameter such that the saw teeth above the mounting are pointing towards you.
•  Push a spacer onto the mounting.
•  Repeat the procedure with saw blade and spacer in the same sequence twice more.
• Fit the front flange with the integrated flange screw into the bore and twist the flange while exerting a slight pressing movement until the flange engages.

Reversible knife change and setting “Adjustable groove cutter”
The adjustable groove cutter 30 (Fig. 9) is equipped with 4 carbide reversible knives 32 and 4 carbide precutters 33. If the blades are becoming blunt, you can turn the reversible knife 32 (Fig. 9) thrice and the reversible knife 33 (Fig. 9) twice. After that, new original reversible knives must be fitted!
Proceed as follows:

• Dismantle the adjustable groove cutter 30 (Fig. 9) from the machine as described in 4.8.
•  Unscrew the countersunk screws 34 (Fig. 9) using the torx screw driver.
•  Clean all parts and the knife chambers of the adjustable groove cutter.
• Turn or replace the reversible knives 32 and 33.
• Fasten the reversible knives with the countersunk screws and retighten these with the torx screw driver (4 Nm).
  The two parts have been inserted correctly if the rear of a knife edge is resting against the carrier body and the countersunk screw can be screwed in that far that the surface of the countersunk screw is located below or on the same level as the surface of the reversible knife (see Fig. 9). The radial blade protrusion of max. 1.1 mm (3/64 in.) is thus guaranteed.

Reversible knife change and setting “Plasterboard milling cutter”
The plasterboard milling cutter 35 (Fig. 10) is equipped with 2 carbide reversible knives (4-blade) and 4 carbide reversible knives (3-blade). If the blades are becoming blunt, you can turn the reversible knife 36 (Fig. 10) twice and the reversible knife 37 (Fig. 10) thrice. After that, new original reversible knives must be fitted!
Proceed as follows:

•  Dismantle the adjustable groove cutter 35 (Fig. 10) from the machine as described in 4.7.
•  Unscrew the countersunk screws 34 (Fig. 10) using the torx screw driver.
• Clean all parts and the knife chambers of the plasterboard milling cutter.
• Turn or replace the reversible knives 36 and 37.
• Fasten the reversible knives with the countersunk screws and retighten these with the torx screw driver (4 Nm).
  The two parts have been inserted correctly if the rear of a knife edge is resting against the carrier body and the countersunk screw can be screwed in that far that the surface of the countersunk screw is located below or on the same level as the surface of the reversible knife (see Fig. 10). The radial blade protrusion of max. 1.1 mm (3/64 in.) is thus guaranteed.

Aluminium compound milling cutter
Aluminium compound milling plates cannot be turned as they are soldered in. (A blunt tool must be reground).

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 o n: First unlock the switch-on lock by pressing the locking lever 7 (Fig. 5). 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 reduces the motor output in case of an overload, i.e. the tool stops. Switch the machine off then. Then switch the machine on again and continue sawing at a reduced feed speed.
  • The setting wheel 9 (Fig. 3) can be used to adjust the tool speed in a continuously variable manner between 3600 and 6250 rpm.

• Material groups

  • PVC, plexiglass, PA, aluminium compound
    Level: 1 – 6

  • Hardwood, softwood, plywood
    Level: 3 – 6

  • Coated panel materials
    Level: 4 – 6

  • Plaster
    Level: 3 – 5

• Switching off: To switch off, release the gearshift lever 8. The built-in automatic brake limits the slowing time of the tool to approx. 5 s. The switch-on lock is automatically reactivated and secures the groove-cutting machine against accidental switch-on.

Incising the guide rail (special accessories)
Danger- Initial start-up Trim the splinter guard 38 (Fig. 4) with the saw blade prior to initial start-up:

• Place the rail onto a level support.
•  Put down the machine at the start of the rail with the groove 24 (Fig. 6) in the base plate on the spring of the rail.
• Set the cutting depth to approx. 3 mm (1/8 in).
• Switch on the machine and slide it evenly in cutting direction across the entire length. The newly formed cut edge on the splinter guard serves as tracing edge for the saw blade, the adjustable groove cutter and the slitting unit.
• Place the rail onto the workpiece.
• Push it against the workpiece and align it with the marking. In order to fix the rail, clamp the rail with the two screw clamps (special accessories) 39 (Fig. 8).
• Set the cutting depth at the machine.
•  Switch on the machine and slide it evenly in cutting direction.
• Do not clean the rail with solvents – the anti-skid coating could get damaged.

Cutting depth adjustment
The cutting depth can be set between 0 and 26 mm (0 and 1 1/32 in.), graded in 1 mm (3/64 in.) steps.

Proceed as follows:

• Adjust the indicator 10 (Fig. 8) by turning. The top position is for working with guide rail, the bottom position for working without guide rail.
• Set the cutting depth with the depth stop 11 (Fig. 5) according to the scale. The limit stop has a 1 mm (3/64 in.) latching mechanism.
•  To set intermediate measures, turn the cylinder head bolt 12 (Fig. 5) with the Allen key 4 (brackets Fig. 2). One turn corresponds to 1 mm (3/64 in.), one scale line on the screw head corresponds to 0.1 mm (1/128 in.).

Grooves
Set the desired cutting depth according to chapter 5.4.
Carry out groove cutting using a guiding device. Wider grooves are achieved by laterally offsetting the guiding device from the right to the left.

Handling
Danger
The groove-cutting machine is not suitable for freehand guidance. The use of parallel stop, roller edge guide, KSS rail or F-rail guide is compulsory. In case of the KSS model, place the workpiece onto the support frame in a stable manner.

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!

Working according to marking
The base plate has two fixed marking indicators 17 and 25 (Fig. 1). Marking indicator 25 corresponds to the centre of the plasterboard and aluminium compound milling cutter. Marking indicator 17 corresponds to the inside of the saw blade, adjustable groove cutter and slitting unit.

• Always use a guiding device.
• Secure the workpiece against dislocation and arrange the workpiece supports such that the tool underneath the workpiece is running freely (in case of a severing cut).
• Hold the machine by the handle and place the front part of the base plate onto the workpiece.
• Switch on the groove-cutting machine (see 5.2). Plunge to the set cutting depth and slide the machine evenly forward in the direction of the cut.
• After the end of the cut, switch off the groove-cutting machine by releasing the gearshift lever 8 (Fig. 5).
• While it is resting on the workpiece, pull the machine back into home position and in this position remove it from the workpiece. Proceeding in this manner ensures that the retractable saw guard is completely closed. The saw unit tilts back into the top locked position.

Working with the parallel stop

• The parallel stop 18 (Fig. 2) is used 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. 170 mm (6 45/64 in.)and on the left-hand side to approx. 345 mm (13 37/64 in.).
  • When working with the parallel stop, set the cutting depth indicator 10 (Fig. 8) by turning it into the bottom position (without rail).
  • The rods of the parallel stop have a scaling, which refers to the left-hand side of the saw blade.
  • You can adjust the cutting width after releasing the wing screws 19 (Fig. 2) by moving the limit stop accordingly and afterwards retightening the wing screws.
• In addition, by simply turning it around, the parallel stop can also be used as double support to improve groove-cutting machine guidance (guide surface for the workpiece edge is pointing upwards). Now the machine can be guided along a lath that is fastened on the workpiece.

Working with the roller edge guide
The parallel stop 20 (Fig. 3) is used 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. 0 – 100 mm (0 – 3 15/16 in.) and on the left-hand side to approx. 23 – 230 mm (29/32 – 9 1/16 in.).

•  When working with the roller edge guide, set the cutting depth indicator 10 (Fig. 8) by turning it into the bottom position (without rail).
• The rods of the parallel stop have a scaling, which refers to the left-hand side of the saw blade.
•  You can adjust the cutting width after releasing the wing screws 19 (Fig. 2) by moving the limit stop accordingly and afterwards retightening the wing screws.
  Now the machine can be guided along a narrow workpiece running below the base plate.

Setting for mitre cuts (only for KSS design)

• Release the limit stop 40 (Fig. 7) and adjust the angle according to the scale on the guide rail.
  Retighten the limit stop.

•  Using the two stop bolts on the bottom side of the guide rail, apply the machine to the workpiece to be machined. Then carry out the cut by advancing the machine.

•  After the cut, return the saw to its starting position by retracting it.

Quick adjustment of the repeater stops 43 (Fig. 7)

•  Using the Allen key 4 (Fig. 2), turn the hexagonal bolt in the repeater stop by approx. ½ revolution counter clockwise.
• Push the repeater stop against the permanently set stop from the side facing away from 0°, so that it rests behind the stop.
• Tighten the hexagonal bolt in the repeater stop.
• Also set the repeater stop on the opposite 0°side accordingly.

Working with guide rail

• Place the machine onto the guide rail such that the groove 24 (Fig. 6) of the base plate rests above the spring and is guided by it.
•  Set the cutting depth indicator 10 (Fig. 8) into the top position by turning (with rail). Thus, the scale can also be used with the rail.

Working with position indicator
Use the position indicator to align the guide rail to a centre marking of the guide groove. It is included with the machine or tools (for plasterboard milling cutter and aluminium compound milling cutter).
Proceed as follows:

• Fit the position indicator 42 (Fig. 6) onto the rib of the guide rail.
•  Move the position indicator on the rail up to the marking.
•  Move the rail with position indicator until the front (red edge) of the marking indicator agrees with the marking.
•  Place the machine onto the rail (the tool is now aligned with the centre of the marking).
• Set the required milling depth and machine the workpiece.

Removing / fitting onto KSS rail

• Remove:
  • Slide the machine forward on the rail by 2-3 cm (25/32 – 1 3/16 in.).
  • Actuate the ratchet 41 (Fig. 5) and pull the machine to the rear out of the guide rail.
• Attaching:
  • Place the machine onto the guide rail in the rear guide rail area such that the groove 24 (Fig. 6) on the front of the base plate agrees with the spring of the guide rail (overlap on the left-hand base plate side approx. 5 – 10 mm, 13/64 –25/64 in.).
  •  Slide the machine forward until the ratchet engages behind the base plate.

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
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.

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.

fuses
Machine overloaded| Reduce feed speed
Tool jams when advancing the machine| Feed rate too fast| Reduce feed speed
Blunt tool| Release the switch immediately. Remove machine from the workpiece and exchange tool
Tension in the workpiece|
Poor machine guidance| Use parallel stop
Uneven workpiece surface| Straighten the surface
Burn marks on the cut surfaces| Tool unsuitable or too blunt for the work process| Replace tool
Chip ejection blocked| Wood is too damp|
Extended operation without extraction| Connect to an external extraction,

e.g. portable dust extractor

Special accessories

• Saw blade-TCT 120 x 1.8 x 20 mm (4 47/64 x 5/64 in. x 20 mm), 12 teeth (longitudinal cut) Order No. 092560
• Saw blade-TCT 120 x 1.8 x 20 mm (4 47/64 x 5/64 in. x 20 mm), 24 teeth (longitudinal and cross cuts) Order No. 092558
• Saw blade-TCT 120 x 1.8 x 20 mm (4 47/64 x 5/64 in. x 20 mm), 40 teeth (cross cut) Order No. 092559
• Saw blade-TCT 120 x 1.2 x 20 mm (4 47/64 x 3/64 in. x 20 mm), 40 teeth (for laminate) Order No. 092578
• 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 Qty.) Order No. 205399
  • Connecting piece F-VS Order No. 204363
  • Rail bag F160 Order No. 204626
• 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
• Backlash stop F-RS Order No. 202867
• Roller edge guide MF-UA, cpl. Order No. 206073
• Slitting unit MF-SE3 Order No. 206072
• Adjustable groove cutter MF-VN25 Order No. 206074
• Plasterboard milling cutter MF-GF45 with 2 position indicators Order No. 205562
• Plasterboard milling cutter MF-GF90/15 with 2 position indicators Order No. 206590 f>
• Aluminium compound milling cutter MF-AF90 with 2 position indicators + chip deflector Order No. 206076
• Suction hose LW 35, 4 m antistatic Order No. 093717
• Guiding device (only for wood – KSS) Order No. 204387

Material selection / tool selection

Materials

Tools

| Wood / wood- based material boards| Plaster / plasterboard| Aluminium compound panels| Laminate panels
---|---|---|---|---
Carbide saw blade| X| X| X| X
Slitting unit| X| X|  |
Adjustable groove cutter| X|  |  |
Plasterboard milling cutter| X| X|  |
Aluminium compound milling cutter|  |  | X|

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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