mafell KSS40 18M bl Cordless Cross-Cutting System Instruction Manual

KSS40 18M bl Cordless Cross-Cutting System
**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 KSS40 18 M bl complies with the EU directives quoted. The standards listed were used for design and construction. The empowered person for the configuration of the technical documents: Mafell AG

Signs and symbols

This symbol appears at places where you will find instructions for your own safety.
Non-compliance with these instructions may result in very serious injuries.
This symbol indicates a potentially hazardous situation.
If this situation is not avoided, the product or objects in its vicinity may get damaged.
This symbol indicates tips for the user and other useful information.

Product information

in respect of machines with item numbers 91B301, 91B302, 91B321, 91B323, 91B325 or 91B348
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
2.2 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 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.
| Protect the rechargeable battery from heat, excessive solar radiation, fire, frost, water, and humidity.
Protect rechargeable battery packs from the humidity!
| Protect rechargeable battery packs from fire!
There is a danger of an explosion!
| Cordless Alliance System (=CAS) is a cross-manufacturer battery pack system.
Further information is available at www.cordless-alliance-system.com

Technical data

Nominal voltage
Saw blade speed while idling
Cutting depth 0º/45º
Tilting saw unit
Saw blade diameter max/min
Saw blade body thickness
Tool cutting width
Saw blade mounting hole
Hose connector diameter
Weight with a rechargeable battery, without parallel stop
Dimensions incl. guide assembly (W x L x H)| 18 V
6700
rpm
42/29 mm (1 21/32, 1 9/64 in.)
0 – 45º
122/112 mm (4 51/64, 4 13/32 in.)
1.2 mm (3/64 in.)
1.8 mm (0.070 in.)
20 mm
28 mm (1 7/64 in.)
2.8 kg (6.2 lbs)
200 x 580 x 200 mm (7 7/8 x 21 21/32 x 7 7/8 in.)
---|---

as cross-cutting system

Cutting depth 0°/45°………………………….40/27 mm (1 9/16, 1 1/16 in.)
Cutting length at 12/40 mm workpiece thickness………………………….337/292 mm (13 ¼, 11 ½ in.)
Weight with rechargeable battery and guide assembly…………………………….3.6 kg (7.9 lbs)

2.4 Emissions
The values stated are emission levels. Although there is a correlation between emission and emission level, it cannot be reliably derived from this whether additional precautions are necessary. Factors influencing the current immission level existing at the workplace comprise the duration of exposure, the room characteristic, other sources of noise, etc. such as e.g. the number of machines and other adjacent machining operations. In addition, the permissible immission level may differ from country to country. This information is nevertheless suitable for providing the machine user with an improved assessment of the hazard and risk.
2.4.1 Noise emission specifications
Noise emission values determined according to EN 62841:

The noise measurement was recorded using the saw blade included in the standard equipment.
2.4.2 Vibration specifications
The typical hand-arm vibration is less than 2.5 m/s2
2.5 Scope of supply
Cross-cutting system KSS40 18 M bl complete with:

• 1 carbide-tipped circular saw blade Ø 120 mm (4 ¾ in.), 24 teeth
• 1 riving knife/splitter (thickness 1.2 mm / 3/64 in.)
• 1 hose connector
• 1 parallel stop
• 1 service tool in the bracket on the machine
• 1 carrying case Max
• 1 operating manual
• 1 folder “Safety Instructions”
• 2 clamping claws for Item No. 91B301, 91B321, 91B323, 91B325
• 1 FLEXI rail FX 140 for cutting length max. 140 cm (55 in.) for Item No. 91B301, 91B321, 91B323, 91B325
• 1 charger APS 18 M for Item No. 91B301, 91B321, 91B323, 91B325
• 2 rechargeable batteries 18 M 99 LiHD for Item No. 91B301, 91B321, 91B323, 91B325
• 1 chip bags

2.6 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 stationery saw guard
– Lower retractable saw guard
– Large base plate
– Handles
– Riving knife/splitter
– Index mechanism and brake
– Hose connector

2.7 Use according to the intended purpose
The MAFELL cross-cutting system is exclusively suited for longitudinal and cross-cutting of solid wood. Panel materials such as chipboard, core board, and medium-density fibreboard can also be processed. Use approved saw blades according to EN 847-1. Any other use than described above is not permissible. The manufacturer cannot be held liable for any damage arising from such other use. So as to use the machine as intended, comply with the operating, maintenance, and repair instructions specified by Mafell.
Use only original Metabo or CAS (Cordless Alliance System) battery packs and accessories.
Battery packs marked with CAS are 100% compatible with CAS devices (Cordless Alliance System).
2.8 Residual risks
Danger
Even if used in accordance with its intended purpose and despite confirming the safety instructions, residual risks caused by the intended use will always remain.

– Touching the saw blade in the vicinity of the starting aperture below the base plate.
– Touching the part of the saw blade that protrudes below the workpiece when cutting.
– Touching of turning parts from the side: saw blade, clamping flange, and flange screw.
– Machine backlash if the blade gets stuck in the workpiece.
– Breakage of the saw blade and risk of the blade or pieces of the blade being hurled away.
– Accidental activation if the rechargeable battery is not unplugged.
– Hearing can be impaired when working for long periods without ear protectors.
– Emission of harmful wood dust during longer operation without extraction.
– Snapping open of the FLEXI rail if used improperly.

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 stipulated for the respective operating sequence and do not affect any modifications on the machine that could impair safety.
– Protect the machine and the rechargeable batteries from the 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.
– Ensure that the machine is switched off when you push in the rechargeable battery.
– Please remove the rechargeable battery from the machine if the machine is put down, transported or stored unattended.

Do not use:
– Cracked and misshapen saw blades.
– Saw blades are made of high-speed steel (HSS saw blades).
– Blunt saw blades as they impose an excessive load on the motor.
– Saw blades with a base body with a thickness greater than, or a cutting width (setting) less than, the thickness of the riving knife/splitter.
– Saw blades that are not suitable for the saw blade’s idling speed.
– Grinding discs
Instructions on the use of personal protective equipment:
– Always wear ear protectors during work.
– Always wear a dust mark during work.

Instructions on operation:

Sawing method
** Danger
– Keep hands away from the cutting area and the blade. Keep your second hand on the 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 minimize 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 the 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 a loss of control.
– Never use damaged or incorrect blade washers or bolts. 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 anuncontrolled 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 backward, but kickback forces can be controlled by the operator, if proper precautions are taken.
– When the 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, center the saw blade in the kerf so that the saw teeth are not engaged in the material. If a saw blade binds, it may walk up or kick back from the workpiece as the saw is restarted. Support large panels to minimize 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.
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 the 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. The 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 the 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 the switch is released.
Riving knife function
– 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 shortcuts.
– Do not operate the saw if the riving knife is bent Even a light interference can slow the closing rate of a guard.
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

4.1 Charging the rechargeable battery
Check whether the rated voltage of the rechargeable battery agrees with the information specified on the machine.
The rechargeable battery and charger are matched to each other. Only use the MAFELL – APS 18 chargers for recharging.
Before using a new machine, first of all charge the rechargeable battery.
A description of how to start up and charge the APS 18 can be found in the appended instructions “APS 18 rechargeable power station”. 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.
4.2 Fitting the rechargeable battery
Slide the charged rechargeable battery into the battery guide behind the handle until it perceptibly engages
Before using the machine, convince yourself that the rechargeable battery is firmly seated in the machine.
4.3 Removing the rechargeable battery
Unlock the rechargeable battery by pressing the locking lever 1 (Fig. 3) and pulling it out of the battery guide.
Do not use force to do so.
4.4 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 3 (Fig. 3) is 28 mm (1 7/64 in.).
4.5 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 or hardwood:
– Circular saw blade carbide Ø 120 x 1.8 x 20 mm (4 ¾ x 5/64 in. x 20 mm), 24 teeth
For cuts especially along the grain in soft or hardwood:
– Circular saw blade carbide Ø 120 x 1.8 x 20 mm (4 ¾ x 5/64 in. x 20 mm), 12 teeth
For cuts especially across the grain in soft or hardwood:
– Circular saw blade carbide Ø 120 x 1.8 x 20 mm (4 ¾ x 5/64 in. x 20 mm), 40 teeth
For cuts in laminate:
– Circular saw blade carbide Ø 120 x 1.8 x 20 mm (4 ¾ x 5/64 in. x 20 mm), 40 trapezoidal teeth
Order No. see special accessories.
4.6 Saw blade change

**** Danger
Unplug the rechargeable battery for all service work.

1. Press the locking bolt 8 (Fig. 2).
2. Using the Allen-key 3 (brackets Fig. 1), unfasten the flange screw 8 (Fig. 3) counterclockwise; remove the screw as well as the front clamping flange 7.
    Now you can remove the saw blade after opening the retractable saw guard 9.
    The clamping flanges must be free of adhering parts.
    Pay attention to the sense of rotation when inserting the saw blade.
    Afterward, mount the clamping flange, attach the flange screw and tighten it by clockwise turning.
    In doing so, keep the locking bolt depressed.

4.7 Riving knife/splitter
**** Danger

Unplug the rechargeable battery for all service work. The riving knife/splitter 6 (Fig. 3) prevents the saw blade from jamming during longitudinal cutting. The
correct distance to the saw blade is shown in (Fig. 8).

• For adjustment, unfasten screw 4 (Fig. 3) with the Allen key supplied with the saw 3 (Fig. 1).
•  Adjust the riving knife/splitter by shifting it in its longitudinal slit. Afterward, retighten the screw.

Operation

5.1 Initial operation
Personnel entrusted to work with the machine must be made aware of the operating instructions, calling particular attention to the chapter “Safety instructions”.
5.2 Switching on and off

• Switching on: First press the switch-on lock 1 (Fig. 1) and then press the switch trigger 2.
• Switching off: To switch off, release the switch trigger.

5.3 Cutting depth adjustment
The cutting depth is continuously variable between 0 and 40 mm (1 15/16 in.).
Proceed as follows:

• Unfasten the clamping lever 5 (Fig. 1).
• Set the cutting depth with the plunge lever 6 (Fig. 2).
• The cutting depth can be read off the scale 2 (Fig. 5) on the cover. Zone 1 on the plunge lever with the red background serves as indicator for this purpose.
• Retighten the clamping lever.

Always set the cutting depth approx. 2 to 5 mm (5/64 to 13/64 in.) larger than the material thickness to be cut.
5.4 Setting for bevel cuts
For bevel cuts, the saw unit can be set to any angle between 0° and 45°.

• Unfasten the wing screws 5 (Fig. 3).
• Adjust the angle according to the scale on the segment for tilting.
• Afterward, tighten the wing screws 5.

5.5 Setting for miter cuts

• Release the limit stop 21 (Fig. 7) and adjust the angle plate according to the scale on the guide rail.
• Afterward, retighten the limit stop.
• Place the machine with the two stop bolts at the bottom side of the guide rail against the workpiece to be processed and carry out the cut by pushing the machine forward.
• After the cut, return the saw to its original position by reversing.

5.6 Plunge cuts

Danger
Risk of backlash during the 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!

• Unfasten the clamping lever 5 (Fig. 1) on the switched-off machine.
• Reset the plunge lever 6 (Fig. 2).
• Open the retractable saw guard with lever 2 (Fig. 3) so that the machine can be placed onto the workpiece to be machined. The saw blade is now running freely above the material and can be aligned for tracing.
• Switch on the machine only now.
• Push the plunge lever 6 (Fig. 2) vertically downwards so that the saw blade plunges vertically into the workpiece. While doing so, the plunge depth can be read off the scale 2 (Fig. 5). The riving knife/splitter swings up and away when the blade enters the workpiece. As soon as the slit behind the saw blade is cleared during the forward motion of the machine, the riving knife reverts to its normal position.

5.7 Sawing with FLEXI rail
Danger
The support rail is pre-tensioned and may snap open in an uncontrolled manner – the risk of injury. It should therefore be securely held with both hands during opening and closing.
Initial operation
Trim the splinter guard 4 (Fig. 4) before initial operation:

• Place the FLEXI rail on a flat support.
• Set the cutting depth to approx. 3 mm ( 1/8 in. ) and the angle scale to 0°.
• Turn on the machine and push it evenly in the direction of the cut. The resulting cut edge on the splinter guard serves as a tracing edge for straight cuts and bevel cuts.
• Place the FLEXI rail onto the workpiece. Knock against the workpiece and align it on the tracing. So as to fix the FLEXI rail, tighten the two clamping claws 1 (Fig. 6) with the screw clamps.

Operating method

• Set the cutting depth and cutting angle on the machine.
• Place the machine on the start of the FLEXI rail such that the guide elements 1 (Figure. 4) of the rail engage in the base plate groove.
• Turn on the machine and push it evenly in the direction of the cut.

Do not clean the FLEXI rail with solvents. The non-skid coating may get damaged.

5.8 Sawing shadow gaps
The minimum shadow gap width is:

– if used without parallel stop 13 mm (33/64 in.)
– if used with parallel stop 14 mm (35/64 in.) (at cutting depth of 0 – 32 mm / 0 – 1 ¼ in.)
– if used with parallel stop 18 mm (45/64 in.) (at cutting depth of 32 – 42 mm / 1 ¼ – 1 21/32 in.)

• Set the required cutting depth.
• Retract the retractable saw guard with lever 2 (Fig. 3) and set the machine onto the first fitted workpiece.
• Switch on the machine and push the machine evenly in the cutting direction, in addition using the extraction device.

5.9 Sawing with parallel stop

The parallel stop 4 (Fig. 1) 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 approx. 65 mm (2 9/16 in.) and on the left-hand side to approx. 250 mm (9 27/32 in.).
You can adjust the cutting width after unfastening the wing screws 9 (Fig. 2) by moving the limit stop accordingly and afterward refastening the wing screws.
In addition, by simply turning it over (the guide surface for the workpiece edge is pointing upwards), the parallel stop can be used as double support to improve machine guidance. Now the machine can be guided along with a lath that is fastened on the workpiece.
5.10 Sawing according to tracings with guide rail
When sawing according to tracing, the right edge of the guide rail serves as a tracing indicator. This also applies to bevel cuts. Please take note of Section 5.4.

• For sawing, place the guide rail onto the workpiece.
• Switch on the machine (see Chapter 5.2) and slide the machine evenly in the cutting direction.
• When the cut is completed, switch off the saw by releasing the switch trigger 2 (Fig. 1)
• While it is resting on the workpiece, pull the machine back into the home position and in this position remove it from the workpiece. Proceeding in this manner ensures that the retractable saw guard is completely closed.

5.11 Sawing according to tracings without guide rail
Danger
When sawing without a guide rail it is imperative to install the enclosed parallel stop. It serves as double support to improve machine guidance and is for your safety.
Set the machine’s cutting depth to at least 30 mm (1 3/16 in.). Afterward, you can remove the machine from the guide rail to the rear by actuating the lockinglever 20 (Fig. 7).
The base plate is equipped with a tracing edge 10(Fig. 3) both for straight cuts and for bevel cuts. This tracing edge corresponds to the saw blade’s inside.
For bevel cuts, the tracing can be viewed through the opening on the left-hand side of the upper saw guard.

• Hold the machine by its handles and place the front part of its base plate onto the workpiece.
•  Switch on the machine and evenly advance the machine in the cutting direction.
• When the cut is completed, switch off the saw by releasing the switch trigger 2 (Fig. 1).

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 handing the machine in at an authorised MAFELL customer service shop for inspection.
Only use our special grease, order No. 049040 (1 kg tin) for all greasing points.
6.1 Storage
If the machine is not used for a longer period of time, it has to be carefully cleaned. Spray bright metal parts with a rust inhibitor.
6.2 Transport
The contained lithium-ion batteries are subject to the Dangerous Goods Legislation requirements. The user can transport the batteries by road without further requirements.
When being transported by third parties (e.g.: air transport or forwarding agency), special requirements on packaging and labeling must be observed. For the preparation of the item being shipped, consulting an expert for hazardous material is required.
Dispatch batteries only when the housing is undamaged. Tape or mask off open contacts and pack up the battery in such a manner that it cannot move around in the packaging.
Please also observe possibly more detailed national regulations.
6.3 Disposal of rechargeable batteries/batteries
The machine, rechargeable batteries, accessories and packaging should be sorted for environmental-friendly recycling.
Do not dispose of power tools and atteries/rechargeable batteries into household waste!
Only for EC countries:
According to the European Guideline 2002/96/EC, power tools that are no longer usable, and according to the European Guideline 2006/66/EC, defective or used battery packs/batteries, must be collected separately and disposed of in an environmentally correct manner.
Battery packs/batteries:
Li-Ion:
Please observe the instructions section “Transport”, page 29.
Subject to change without notice.

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.

the rechargeable battery
Rechargeable battery not engaged in the end position| Allow the rechargeable battery to engage completely
Rechargeable battery almost empty, an LED on the
the rechargeable battery is flashing.| The electronic system protects the rechargeable battery from deep discharge.| Check, press button 11. Fig. 1 + 7

• 9
  Only one LED is still glowing. Charge the rechargeable battery.
  Overload, the machine switches off.| A sustained load has overheated the machine or the rechargeable battery. A warning signal is sounded (constant bleeping).
  It will go out after max. 30
  seconds or after the switch trigger is released.| 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. 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.
  Afterward, you can switch the
  machine back on again and
  resume work as normal.
  Try to avoid further blockages.
  Saw blade jams when the machine is advanced.| Feed rate too fast| Reduce feed speed
  Blunt saw blade| Release the switch immediately.
  Remove the machine from the workpiece and replace the saw blade
  Tension in the workpiece|
  Poor machine guidance| Use parallel stop
  Uneven workpiece surface| Straighten the surface
  Defect| Cause| Remedy
  ---|---|---
  Bum marks on the cut surfaces| The saw blade used is unsuitable for the task or blunt| Replace saw blade
  Chip ejection blocked| The wood is too damp|
  Extended operation without
  extraction| Connect to an external extraction, e.g. portable dust extractor

Special accessories

– Saw blade carbide Ø 120 x 1.8 x 20 mm (4 ¾ x 5/64 in. x 20 mm), 12teeth (longitudinal cut)| Order No. 092560
---|---
– Saw blade carbide Ø 120 x 1.8 x 20 mm (4 ¾ x 5/64 in. x 20 mm), 24
teeth (longitudinal and cross cuts)| Order No. 092558
– Saw blade carbide Ø 120 x 1.8 x 20 mm (4 ¾ x 5/64 in. x 20 mm), 40
teeth (cross cut)| Order No. 092559
– Saw blade carbide Ø 120 x 1.8 x 20 mm (4 ¾ x 5/64 in. x 20 mm), 40
teeth (laminate)| Order No. 092578
– FLEXI rail FX 140, cpl.| Order No. 204372
– Accessories for FLEXI rail:|
– Screw clamp| Order No. 093281
– Extraction device S 50 M| Order No. 915901
– Extraction device S 25 M| Order No. 919710
– Suction device S 25 L| Order No. 919715
– Extraction device S 35 M| Order No. 919701
– Akku-PowerTank 18 M 144 LiHD| Order No. 094498
– Akku-PowerTank 18 M 99 LiHD| Order No. 094503
– APS 18 M charger – GB| Order No. 094493
– APS 18 M charger/- Guiding device S packed| Order No. 094492

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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