Mafell MT 55 18 M bl Mode d'emploi

MT55 18M bl

170701.0922/b

IMPORTANT

Read Before Using

IMPORTANT

Lire avant usage

IMPORTANTE

Leer antes de usar

Operating/Safety Instructions

Consignes d’utilisation/de sécurité

Instrucciones de funcionamiento y seguridad

For English Version

See page 2

Version française

Voir page 31

Versión en español

Ver la página 60

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English

Table of contents

1 Signs and symbols ........................................................................................................... 3

1.1 Identification of the device ................................................................................................ 5

2 Product specifications ...................................................................................................... 5

2.1 Technical data .................................................................................................................. 6

2.2 Scope of delivery .............................................................................................................. 6

2.3 Adjustment elements ........................................................................................................ 7

3 General safety .................................................................................................................. 8

3.1 Intended use ..................................................................................................................... 8

3.2 Foreseeable misuse ......................................................................................................... 8

3.3 Safety instructions ............................................................................................................ 9

3.4 Specific safety rules ....................................................................................................... 10

3.5 Safety devices ................................................................................................................ 13

3.6 Residual risks ................................................................................................................. 14

4 Setup / adjustment ......................................................................................................... 14

4.1 Charging the rechargeable battery ................................................................................. 14

4.2 Inserting the rechargeable battery .................................................................................. 15

4.3 Removing the rechargeable battery ............................................................................... 15

4.4 Chip extraction ............................................................................................................... 16

4.5 Saw blade selection ....................................................................................................... 16

4.6 Changing the saw blade ................................................................................................. 17

5 Operation ........................................................................................................................ 19

5.1 Startup ............................................................................................................................ 19

5.2 Switching on ................................................................................................................... 19

5.3 Switching off ................................................................................................................... 19

5.4 Cutting depth setting ...................................................................................................... 20

5.5 Setting for bevel cuts ...................................................................................................... 21

5.6 Plunge cuts ..................................................................................................................... 22

5.7 Sawing along markings .................................................................................................. 22

5.8 Sawing with the parallel guide fence .............................................................................. 23

5.9 Working with special accessories ................................................................................... 24

6 Service and maintenance ............................................................................................... 27

6.1 Storage ........................................................................................................................... 27

6.2 Transport ........................................................................................................................ 27

6.3 Disposal of a rechargeable battery ................................................................................. 27

7 Troubleshooting .............................................................................................................. 28

8 Optional accessories ...................................................................................................... 30

9 Exploded view and spare parts list ................................................................................. 30

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1 Signs and symbols

These operating instructions contain the following general information signs to guide you, the reader, through

the operating instructions and to provide you with important information.

Sign

Meaning

Important information

This sign highlights user tips and other useful information.

➢

Identifies an intermediate result in a sequence of actions.

✓

Identifies the final result of a sequence of actions.

Tab. 1: General signs and their meanings

Warning icons warn of dangerous points, risks and obstacles.

Icon

Meaning

Warning

This icon can be found at all locations where you can find information regarding your

safety. Non-observance can result in extremely serious injuries.

Warns of danger of electric shock.

Warns of danger caused by dust.

Warns of the danger of cutting.

Warns of the danger of cutting off or severing limbs.

Tab. 2: Warning icons and their meanings

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Mandatory icons are intended to prevent accidents.

Icon

Meaning

Wear eye protection.

Wear dust mask.

Wear hearing protection.

Wear protective gloves.

Tab. 3: Mandatory icons and their meanings

During the operation of the power tool there are always actions to be taken where hazards can occur. These

potentially dangerous actions are preceded by warnings which must be observed.

Classification of the danger level (signal words) of warnings

Warning

Meaning and consequences of non-observance

Imminent danger that will cause serious or fatal injuries.

Potentially dangerous situation that can cause serious or

fatal injuries.

Potentially dangerous situation that can cause minor

injuries.

Tab. 4: Structure of warnings

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1.1 Identification of the device

The icons listed and explained below can be found on the rating plate or on the product.

Symbol

Explanation

Symbol

Explanation

V

Volt

1, 2, 3, ...

I, II, III, ...

Rotational speed setting

A

Ampere

rpm

Revolutions per minute

Hz

Hertz

ø

Saw blade diameter

W

Watt

~

Alternating current

kg

Kilogram (weight)

Protection class II

min

Minutes (time)

Read operating instructions

s

Seconds (time)

Protective goggles

n0

Rated speed at no load

Hearing protection

n

Rated speed at normal load

Dust mask

Cordless Allicance System (=CAS) is a cross-manufacturer battery pack

system. Further information is available at www.cordless-alliance-system.com

2 Product specifications

for machines with item number 91B423, 91B424

The article number and machine number are listed on the type plate of the machine.

By entering the article number and machine number on the MAFELL homepage, you can

call up the spare parts lists, exploded drawings, and other product information belonging

to your machine (see also Chapter 9 Exploded view and spare parts list).

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2.1 Technical data

Rated voltage

18 V, DC

Saw blade speed at no load

4850 rpm

Cutting depth

0°: 0 - 57 mm [0 - 2.24 in]

30°: 0 to 46 mm [0 to 1.81 in]

45°: 0 - 35 mm [0 - 1.38 in]

Saw unit swivel range

-1° / 0°– 48°

Saw blade diameter max/min

162/149 mm [6.38/5.87 in]

Saw blade body thickness

1.2 mm [0.05 in]

Tool cutting width

1.8 mm [0.07 in]

Saw blade mounting hole

20 mm [0.8 in]

Hose connector diameter

35 mm [1.4 in]

Weight with rechargeable battery, without

parallel guide fence

4.5 kg [9.92 lbs]

Dimensions (width x length x height)

250 x 330 x 215 mm [9.84 x 12.99 x 8.46 in]

2.2 Scope of delivery

Fig. 1: Scope of delivery

Components

A

Plunge cut saw

B

Allen key in a holder on the machine

C

Parallel guide fence

D

Transport box

E

Charger APS M

F

2x rechargeable battery 18M 99 LiHD

G

Position indicator

H

Shavings bag

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2.3 Adjustment elements

Fig. 2: Adjustment elements

Adjustment elements on the machine

1

Pointer for cutting depth

2

Cutting depth scale

3

Notch for pre-scoring

4

Switch-on lock

5

Wing screws

6

Operating lever

7

Lever of the rechargeable battery lock

8

Locking lever

9

Pushbutton

10

Swivel slider

11

Setting wheels

12

Tilting segment wing screw

13

Tilting segment scale

14

Swiveling guide fence

15

Slider

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3 General safety

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.

3.1 Intended use

The hand-held circular saw is only suitable for ripping and cross cutting of solid wood.

Panel material such as chip board, core board and medium density fiber board can also be processed.

Processing wood fiber insulation materials is also possible.

Use only saw blades that are approved by the manufacturer.

Using the diamond saw blade allows you to cut fiber cement board as well.

Only use original Mafell / CAS rechargeable batteries and accessories.

3.2 Foreseeable misuse

The machine is not intended for any other use than the intended use listed above.

The manufacturer is not liable for any damage resulting from such other use.

To use the machine as intended, comply with the operating, maintenance and repair conditions specified by

MAFELL.

Foreseeable misuse also includes:

- Tampering with, removing and/or bypassing safety devices of any kind.

- Operating the machine without safety devices.

- Non-observance of safety and warning instructions in the operating instructions.

- Removing the safety and warning labels from the machine.

- Operating the machine by unauthorized persons.

- Failure to follow prescribed maintenance and care instructions.

Never use:

- Cracked and/or deformed 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 that are not suitable for the no-load speed of the saw blade.

- Abrasive wheels.

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3.3 Safety instructions

READ ALL INSTRUCTIONS!

Non-observance of the instructions listed below can cause electric shock, fire and/or serious injuries

.

Work area

- Children and adolescents are not allowed to operate this machine.

- Protect the machine and the rechargeable batteries from moisture.

- Do not throw the rechargeable batteries into a fire.

- Never use defective or deformed rechargeable batteries.

- Never try to open the rechargeable batteries.

- Do not touch or short-circuit the contacts of the rechargeable batteries.

- A slightly acidic, flammable liquid can escape from defective rechargeable batteries! Rinse immediately with

plenty of water if battery fluid gets in contact with your skin. If battery fluid gets into your eyes, wash your

eyes with clean water and seek medical attention immediately!

- Remove the batteries from the machine before you adjust, set up, maintain or clean the machine.

- Ensure that the machine is switched off before you insert the rechargeable battery.

- Remove the rechargeable battery from the machine when you put it down, transport it or store it unattended.

- Do not use this machine when you are tired, or under the influence of drugs, alcohol or medicaments. Be

aware of what you are doing. Stay alert and use common sense.

- Keep children and bystanders at a distance while you are operating the machine. Distractions can cause

you to lose control of the machine.

- Use eye protection, dust mask and hearing protection. Appropriate safety equipment, used

under proper conditions, will reduce the risk of injuries.

Instructions for service and maintenance:

- Cleaning the machine regularly, especially the adjustment elements and the guiding devices, is an important

safety factor.

- Ensure that only genuine MAFELL spare parts and accessories are used. Failure to do so will make

warranty claims and the liability of the manufacturer null and void.

- Prepare a periodic maintenance schedule for your machine. When you clean the machine, be careful

not to disassemble any part of the machine. Reassembling the machine bears the risk that internal

wires are routed incorrectly or pinched, or that return springs of the safety device are mounted

incorrectly. Certain cleaning agents, such as gasoline, carbon tetrachloride, ammonia, etc. can damage

plastic parts.

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- Some of the dust produced by sawing, sanding, drilling and other building work contains chemicals

known to cause cancer, birth defects or other reproductive harm. Some examples of these

chemicals are:

- Lead from lead-based paints,

- Crystalline silica from bricks and cement and other masonry products,

- Arsenic and chromium from chemically treated wood.

Your risk from this hazard varies with the frequency at which you perform this type of work. To reduce your

exposure to these chemicals: Work in a well-ventilated area. Work only with approved safety equipment,

such as dust masks that are specially designed to filter out particles of microscopic size.

3.4 Specific safety rules

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.

Fig. 3: Incorrect sawing vs. correct sawing

- 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 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.

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Kickback - causes and related safety instructions

- Kickback is a sudden reaction to a pinched, jammed or misaligned saw blade, causing an uncontrolled saw

to lift up and out of the workpiece toward the operator;

- When the blade is pinched or jammed tightly by the kerf closing down, the blade stalls and the motor

reaction drives the unit rapidly back toward the operator;

- If the blade becomes twisted or misaligned in the cut, the teeth at the back edge of the blade can dig into the

top surface of the wood causing the blade to climb out of the kerf and jump back toward the operator.

Fig. 4: Kickback of the machine

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.

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- Support large panels to minimise the risk of blade pinching and kickback. Large panels tend to sag

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

near the edge of the panel.

Fig. 5: Incorrect support vs. correct support

- 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.

Function of the guard

- Check the guard for proper closing before each use. Do not operate the saw if the guard does not

move freely and enclose the blade instantly. Never clamp or tie the guard so that the blade exposed.

If the saw is accidentally dropped, the guard may be bent. Check to make sure that the guard moves freely

and does not touch the blade or any other part, in all angles and depths of cut.

- Check the operation and condition of the guard return spring. If the guard and the spring are not

operating properly, they must be serviced before use. The guard may operate sluggishly due to

damaged parts, gummy deposits, or a build-up of debris.

- Assure that the base plate of the saw will not shift while performing a “plunge cut”. Blade shifting

sideways will cause binding and likely kick back.

- Always observe that the 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.

RETAIN THESE INSTRUCTIONS!

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3.5 Safety devices

Danger

Risk of injury from missing safety devices

These devices are necessary for the safe operation of the machine. They must

not be removed or rendered ineffective.

➢ Check the proper functioning of the safety devices before you start

operating the machine.

➢ Never use the machine with missing or ineffective safety devices.

The machine is equipped with the following safety devices:

Safety device

Type of check

Fixed guard

Visual check for damage

Functional check (pushing the saw blade out to full

cutting depth and jerk-free abrupt return to the

upper end position and engaging in this position).

Large base plate

Visual check for damage and deformation

Handles

Visual check for damage

Switching device and brake

Functional check (braking time must not be longer

than 7 seconds)

Hose connector

Visual check for damage and obstruction

If the safety devices are damaged or not functioning properly, follow the instructions in the chapter

Troubleshooting. For other malfunctions, please contact your dealer or MAFELL Customer Service directly.

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3.6 Residual risks

Warning

Risk of injury when working with the machine

Even when the machine is used as intended and in compliance with the safety

regulations, there are still residual risks caused by the intended use, which can

have consequences for your health.

➢ Observe the safety instructions and information in these instructions.

➢ Always be extremely careful and cautious when you work with the machine.

The existing residual risks include:

- Contact with the saw blade in the area of the start-up opening below the base plate.

- Contact with the part of the saw blade that protrudes below the workpiece during the cutting process.

- Contact with rotating parts from the side: Saw blade, clamping flange and flange bolt.

- Kickback of the machine when jammed in the workpiece.

- Breakage and ejection of the saw blade or parts of the saw blade.

- Accidental switch-on when the rechargeable battery is not removed.

- Impaired hearing when working without hearing protection for long periods of time.

- Emission of harmful wood dusts during longer operation without extraction.

4 Setup / adjustment

4.1 Charging the rechargeable battery

Rechargeable battery and charger are matched to each other. Use only the MAFELL chargers for charging.

First, charge the rechargeable battery when you use a new machine.

The charging process is described in the "Charger APS M" instructions supplied.

A significantly shortened operating time after charging indicates that the rechargeable battery is exhausted and

needs to be replaced.

The rechargeable battery is equipped with a temperature monitor. This ensures that the rechargeable battery is

only charged in the optimal temperature range between 0 °C (32 °F) and 50 °C (122 °F). This ensures a long

battery life.

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Warning

Risk of fire and explosion due to overheating or moisture

High temperatures and moisture can cause short-circuits in the rechargeable

battery. There is a risk of fire and explosion.

➢ Protect the rechargeable battery from heat, fire and moisture.

➢ Do not expose the rechargeable battery to temperatures above 50 °C (122

°F).

➢ Store the rechargeable battery at a temperature between 10 °C (50 °F)

and 30 °C (86 °F).

➢ Allow the rechargeable battery to cool down before you start charging it.

4.2 Inserting the rechargeable battery

Prior to inserting the battery, check to ensure that the rated voltage of the rechargeable battery matches the

specification on the machine.

Use the following procedure to insert the

rechargeable battery into the machine:

1. Insert the charged rechargeable battery into

the battery guide until you feel that it locks into

place.

2. Check to ensure that the battery is firmly

seated in the machine.

✓ The rechargeable battery is inserted in

the machine.

Fig. 6: Inserting the rechargeable battery into the machine

4.3 Removing the rechargeable battery

Use the following procedure to remove the

rechargeable battery:

1. Press and hold the lever (7) of the battery

lock.

2. Pull the rechargeable battery out of the guide.

✓ The rechargeable battery is removed.

Fig. 7: Removing the rechargeable battery

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4.4 Chip extraction

Caution

Health hazards from wood dust

The dusts produced during work can be inhaled and can cause health damage.

➢ Harmful dust must be extracted with a HEPA 13 dust extractor.

➢ Wear a dust mask during work.

For all work that produces a significant amount of dust, connect the machine to a suitable external extraction

device. The air velocity must be at least 20 m/s [65 ft/sec].

The inner diameter of the hose connector is 35 mm [1.4 in].

For short-time work that generates a small amount of dust, you can use the shavings bag provided as a self-

suction device.

4.5 Saw blade selection

To achieve good cutting quality, use a sharp tool and select a tool from the following list that is appropriate for

material and application:

Cutting softwood and hardwood across and along the grain direction:

- Carbide circular saw blade Ø 160 x 1.8 x 20 mm, 32 teeth [Ø 6.30 x 0.07 x 0.79 in]

Cutting softwood and hardwood especially along the grain direction:

- Carbide circular saw blade Ø 160 x 1.8 x 20 mm, 16 teeth [Ø 6.30 x 0.07 x 0.79 in]

Cutting softwood and hardwood especially across the grain direction:

- Carbide circular saw blade Ø 162 x 1.8 x 20 mm, 48 teeth [Ø 6.38 x 0.07 x 0.79 in]

Cutting softwood and hardwood especially across the grain direction "fine cuts":

- Carbide circular saw blade Ø 160 x 1.8 x 20 mm, 56 teeth [Ø 6.30 x 0.07 x 0.79 in]

Cutting wood fiber insulation material:

- Carbide circular saw blade Ø 160 x 1.8 x 20 mm, 32 teeth [Ø 6.30 x 0.07 x 0.79 in]

Cutting plastic material (styrofoam):

- Carbide circular saw blade Ø 160 x 1.8 x 20 mm, 16 teeth [Ø 6.30 x 0.07 x 0.79 in]

Cutting fiber cement board:

- Diamond saw blade Ø 160 x 3.0 x 20 mm, 4 teeth [Ø 6.30 x 0.12 x 0.79 in]

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4.6 Changing the saw blade

Caution

Risk of injury from the sharp saw blade

The saw blade is sharp. You can hurt yourself when you change the saw blade.

➢ Wear protective gloves when you change the saw blade.

➢ Be careful when you change the saw blade.

Use the following procedure to change the saw

blade:

1. Pull the rechargeable battery out of the

machine.

2. Put the machine on a flat surface.

3. Press and hold the pushbutton (9).

4. Pull the locking lever (8) upwards.

➢ The guard cover is unlocked and can be

opened sideways. Saw shaft and

operating lever are locked automatically.

Fig. 8: Unlocking the guard cover

5. Open the guard cover sideways.

Fig. 9: Opening the guard cover

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6. Using the Allen key (B), turn the flange screw

(16) counterclockwise to loosen it.

7. Remove the flange screw (16) and the front

clamping flange (17).

8. Remove the old saw blade.

➢ Clamping flanges must be free of

adhering parts!

➢ The new saw blade can now be installed.

Fig. 10: Removing the old saw blade

9. Position the new saw blade (18) on the rear

flange (20).

➢ Ensure that the direction of rotation is

correct when you install the saw blade.

The saw teeth or the arrow on the saw

blade (18) must point in the direction of

the arrow (19) on the machine.

10. Fit clamping flange (17) and flange screw (16).

11. Using the Allen key (B), turn the flange screw

(16) clockwise to tighten it.

➢ The saw blade is secured.

Fig. 11: Replacing the saw blade

12. Close the guard cover.

13. To do this, press the locking lever (8) down.

➢ The mechanism that locks the saw shaft

is activated.

➢ The operating lever is unlocked.

✓ The saw blade is changed.

Fig. 12: Closing the guard cover

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5 Operation

5.1 Startup

These operating instructions must be brought to the attention of all persons entrusted with the operation of the

machine, with particular emphasis on the chapter "Safety instructions".

5.2 Switching on

Use the following procedure to switch on the

machine:

1. Press the switch-on lock (4) forward to unlock.

2. With the switch-on lock depressed, actuate

and hold the operating lever (6).

3. Release the switch-on lock (4).

✓ The machine is switched on

Fig. 13: Switching the machine on

Since the switch is not latching, the machine runs only as long as the operating lever is

pressed. Due to the motor concept used here, the machine stops very quickly when it is

switched off. (Motor brake)

5.3 Switching off

Use the following procedure to switch off the

machine:

1. Release the operating lever (6).

➢ The integrated automatic brake limits the

coasting time of the saw blade to approx.

2 seconds.

➢ The switch-on lock is activated

automatically and secures the hand-held

circular saw against being switched on

inadvertently.

✓ The machine is switched off.

Fig. 14: Switching the machine off

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5.4 Cutting depth setting

The cutting depth can be set continuously in a range between 0 and 57 mm [0 to 2.24 in].

Use the following procedure to set the cutting

depth:

1. Rotate the pointer (1) depending on whether

or not you are working with a guide rail

(optional accessory).

➢ Top position = with guide rail

➢ Bottom position = without guide rail

The cutting depth is reduced by 6 mm [0.24 in]

when a guide rail is used.

Fig. 15: Cutting depth pointer position

2. Use the pointer (1) to set the cutting depth.

➢ The cutting depth is indicated on the

scale (2) on the cover. The scale has a

1-mm graduation.

➢ To readjust the cutting depth setting, you

can use the Allen key (B) to turn the

fillister head screw (21). One revolution

corresponds to a cutting depth change of

1 mm [0.04 in].

✓ The cutting depth is set.

Fig. 16: Setting the cutting depth

For separating cuts, always set the

cutting depth to approx. 2 ... 5 mm

[0.08 ... 0.2 in] more than the

material thickness you want to cut.

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Mafell MT 55 18 M bl Mode d'emploi

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