Mafell LS 103 EC Quick guide

LS 103 Ec
170185.0122/n
Kettenstemmer
Originalbetriebsanleitung
5
Chain mortiser
Translation of the original operating instructions
13
Mortaiseuse à chaînes
Traduction de la notice d'emploi originale
21
Mortasatrice a catena
Traduzione delle istruzioni d’uso originali
29
Kettingfrees
Vertaling van de originele gebruiksaanwijzing
37
Escopleadora
Traducción del manual de instrucciones original
45
Ketjujyrsin
Käännös alkuperäiskäyttöohjeesta
53
Kedjestämmaskin
Översättning av originalbruksanvisningen
61
Kædestemmer
Oversættelse af den originale betjeningsvejledning
69
Цепнодолбежный
станок
Перевод оригинальной инструкции по
эксплуатации
77
Řetězová dlabačka
Překlad původního provozního návodu
86
Dłutownica łańcuchowa
Tłumaczenie oryginalnej instrukcji obsługi
94
Verižni prebijalnik
Prevod izvirnih navodil za uporabo
102

WARNUNG
Lesen Sie alle Sicherheitshinweise und Anweisungen. Versäumnisse bei der Einhaltung der Sicherheitshinweise und
Anweisungen können elektrischen Schlag, Brand und/oder schwere Verletzungen verursachen. Bewahren Sie alle
Sicherheitshinweise und Anweisungen für die Zukunft auf.
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.
AVERTISSEMENT
Veuillez lire toutes les consignes de sécurité et instructions. Tout non-respect des consignes de sécurité et instructions
risque d'être à l'origine de décharges électriques, d'incendies et/ou de blessures graves. Conservez toutes les consignes
et instructions pour pouvoir les relire à tout moment.
AVVERTENZA
Leggere tutte le avvertenze di sicurezza e le istruzioni. La mancanza del rispetto delle avvertenze di sicurezza e delle
istruzioni possono causare scossa elettrica, incendio e/o gravi lesioni. Conservare tutte le avvertenze di sicurezza e le
istruzioni per il futuro.
WAARSCHUWING
Lees alle veiligheidsaanwijzingen en instructies. Nalatigheid bij het naleven van de veiligheidsinstructies en aanwijzingen
kan elektrische schok, brand en/of ernstige letsels veroorzaken. Bewaar alle veiligheidsaanwijzingen en instructies voor
later gebruik.
ADVERTENCIA
Lea todas las indicaciones de seguridad e instrucciones. Si no se cumplen las indicacionesde seguridad e
instrucciones, se pueden producir descargas eléctricas, incendios y/o lesiones graves. Guarde todas las indicaciones de
seguridad e instrucciones para el futuro.
VAROITUS
Lue kaikki turvaohjeet ja käyttöohjeet. Laiminlyönti turvaohjeiden ja käyttöohjeiden noudattamisessa voi aiheuttaa
sähköiskun, tulipalon ja/tai vakavia vammoja. Säilytä kaikki turvaohjeet ja käyttöohjeet tulevaisuuden varalle.
VARNING
Läs alla säkerhetsanvisningar och anvisningar. Underlåtenhet att följa säkerhetsanvisningar och anvisningar kan orsaka
elstötar, brand och/eller allvarliga personskador. Behåll alla säkerhetsanvisningar och anvisning för framtida
användning.
ADVARSEL
Læs alle sikkerhedshenvisninger og instruktioner. En manglende overholdelse af sikkerhedshenvisningerne og
instruktionerne kan føre til elektrisk stød, brand og/eller alvorlige kvæstelser. Opbevar alle sikkerhedshenvisninger og
instruktioner til fremtidig brug.
ПРЕДУПРЕЖДЕНИЕ
Прочитайте все правила и инструкции по технике безопасности. Несоблюдение этих правил и инструкций по
технике безопасности может привести к поражению электрическим током, возгоранию и/или другим серьезным
травмам. Сохраните все правила и инструкции по технике безопасности для дальнейшего использования.
OSTRZEŻENIE
Przeczytać wszystkie przepisy bezpieczeństwa i wskazówki. Zaniedbanie przestrzegania przepisów bezpieczeństwa i
wskazówek może prowadzić do porażenia prądem, pożaru i/lub ciężkich zranień. Zachować wszystkie przepisy
bezpieczeństwa i wskazówki na przyszłość.
UPOZORNĚNÍ
Přečtěte si všechna bezpečnostní upozornění a pokyny. Zanedbání bezpečnostních upozornění a pokynů může způsobit
zásah elektrickým proudem, požár a/nebo vážná zranění. Všechna bezpečnostní upozornění a pokyny si ponechejte pro
pozdější použití.
OPOZORILO
Preberite vsa varnostna opozorila in napotke. Neupoštevanje varnostnih opozoril in napotkov lahko povzroči udar
električnega toka, požar in/ali hude telesne poškodbe. Vsa varnostna opozorila in napotke shranite za prihodnjo
uporabo.

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English
Table of Contents
1Signs and symbols ......................................................................................................... 14
2Product information ........................................................................................................ 14
2.1 Manufacturer´s data .......................................................................................................14
2.2 Machine identification.....................................................................................................14
2.3 Technical data ................................................................................................................ 15
2.4 Emissions....................................................................................................................... 15
2.5 Scope of supply.............................................................................................................. 15
2.6 Use according to intended purpose................................................................................15
2.7 Residual risks ................................................................................................................. 16
3Safety instructions ..........................................................................................................16
4Setting / Adjustment ....................................................................................................... 17
4.1 Mains connection ...........................................................................................................17
4.2 Installation mortising chain set ....................................................................................... 17
4.3 Mortising chain change ..................................................................................................17
4.4 Chain wheel change.......................................................................................................18
5Operation........................................................................................................................18
5.1 Initial operation ............................................................................................................... 18
5.2 Switching on and off .......................................................................................................18
5.3 Cross fence setting......................................................................................................... 18
5.4 Mortising depth adjustment ............................................................................................ 18
5.5 Operating method........................................................................................................... 18
5.6 Mortising recesses .........................................................................................................18
6Service and maintenance...............................................................................................19
6.1 Mortising chains .............................................................................................................19
6.2 Storage...........................................................................................................................19
7Troubleshooting..............................................................................................................19
8Optional accessories ......................................................................................................20
9Exploded drawing and spare parts list ...........................................................................20

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1Signs and symbols
This symbol is found in all places where you will find information for your
safety.
Non-compliance with these instructions may result in very serious injuries.
This symbol indicates a potentially hazardous situation.
If this situation is not avoided, the product or objects in its vicinity may get damaged.
This symbol indicates tips for the user and other useful information.
2Product information
for machines with product no. 924201, 924202, 924203, 924204, 924205, 924206, 924220, 924221, 924222,
924228, 924229, 924235, 924236, 924237, 924238, 924240 or 924250
2.1 Manufacturer´s data
MAFELL AG, Beffendorfer Straße 4, D-78727 Oberndorf / Neckar, Phone [phone], Fax +49
(0)7423/812-218, e-mail: [email protected]
2.2 Machine identification
All details required for machine identification are available on the attached rating plate.
Protection class II
CE symbol to document compliance with the basic safety and health requirements
according to Appendix I of the Machinery Directive.
For EU countries only
Do not dispose of electric tools together with household waste material!
In accordance with the European directive 2002/96/EC on waste electrical and
electronic equipment and transposition into national law, obsolete electrical tools
must be collected separately and recycled in an environmentally-compatible manner.
To reduce the risk of injury, please read the operating instructions.

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2.3 Technical data
Universal motor, radio and TV interference suppressed
230 V~, 50 Hz
120 V~, 60 Hz
Input power continuous operation
2500 W
Current at nominal load
13 A
20 A
Idling speed
4050 rpm
Mortising depth
100 mm (3 15/16 in.)
Mortising depth with guide support stand FG 150, order No. 200
980
150 mm (5 7/8 in.)
Weight without mains cable LS 103 Ec
8,7 kg (19.18 lbs)
Weight guide support stand FG 150, order No. 200 980
4.6 kg (10.1 lbs)
2.4 Emissions
The declared noise emission values have been measured in accordance with DIN EN 62841-1 and may be
used for comparing the tool with another and also in a preliminary assessment of exposure.
Danger
The noise emissions during actual use of the power tool can differ from the declared
values depending on the ways in which the tool is used especially what kind of
workpiece is processed.
Always wear hearing protection, even when the power tool ist running idle in addition
to the trigger time!
2.4.1 Noise emission specifications
Noise emission values determined according to EN 62841:
Sound power level
Workplace-related emission value
Idling
108 dB (A)
97 dB (A)
Machining
108 dB (A)
97 dB (A)
2.4.2 Vibration specifications
The typical hand-arm vibration is 5.1 m/s2.
2.5 Scope of supply
Single-phase chain mortiser LS 103 Ec complete with:
1 guide rail, cpl.
1 mortising chain
1 chain wheel
1 crossfeed stop
2 operating tools
1 operating manual
1 folder “Safety Instructions”
2.6 Use according to intended purpose
The single-phase chain mortiser is exclusively
intended for mortising solid wood using mortising
chains. The dimensions of the mortising chain sets
used (guide rail, mortising chain and chain wheel)
must correspond to the mortising chain sets listed in
the operating instructions.

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Any other use than described above is not
permissible. The manufacturer cannot be held liable
for any damage arising from such other use.
So as to use the machine as intended, comply with
the operating, maintenance and repair instructions
specified by Mafell.
2.7 Residual risks
Danger
Even if used in accordance with its
intended purpose and despite
conforming with the safety
instructions, residual risks caused
by the intended use that can lead
to health consequences will always
remain.
- Touching the mortising chain in the exposed area.
- Touching the part of the mortising chain that
protrudes below the workpiece when mortising.
- Touching the mortising chain from the side .
- Tearing of the mortising chain.
- Backlash of the machine against the operator if the
cross fence is not fastened during freehand milling.
- Touching live parts with the housing open and the
mains plug not removed.
- Hearing can be impaired when working for long
periods without ear protectors.
- Emission of harmful wood dusts during longer
operation without extraction.
3Safety instructions
Danger
Always observe the following safety
instructions and the safety
regulations applicable in the
respective country of use!
General instructions:
- Children and adolescents must not operate this
machine. This rule does not apply to young
persons receiving training and being supervised by
an expert.
- Never work without the protection devices
prescribed for the respective operating sequence
and do not make any changes to the machine that
could impair safety.
- When operating the machine outdoors, use of an
earth-leakage circuit-breaker is recommended.
- Damaged cables or plugs must be immediately
replaced. Replacement may only be carried out by
Mafell or an authorised MAFELL service workshop
in order to avoid safety hazards.
- Avoid sharp bends in the cable. Especially when
transporting and storing the machine, do not wind
the cable around the machine.
Instructions on the use of personal protective
equipment:
- Always wear ear protectors during work.
- Always where a dust mark during work.
Instructions on operation:
- Provide for an unobstructed and slip-proof location
with sufficient lighting.
- The power plug must be pulled before replacing
tools, making adjustments and repairing
malfunctions (this also comprises removing
jammed splinters).
- Do not work on workpieces which are too small or
too large for the capability of the machine.
- Clamp the mortising chain and the guide rail
properly and keep it in good repair. Before reusing
them, repair defective mortising chains
professionally and only use sharp mortising chains!
- Caution: For machines without guide support stand
FG 150, use solely 100 mm (3 5/16 inch) mortising
chain sets!
- Remove the chain guard only for a tool change
and screw it back on again immediately
afterwards. Never work without chain guard!
- Never transport the chain mortiser with running
mortising chain and avoid touching the ground with
the running mortising chain!
- The switch may not be wedged.
- Before switching on the mortising chain, check
whether it is properly tensioned.
- Whenever possible secure the workpiece from
pivoting or sliding away, overturning and luffing up,
e.g by means of clamps.
- Only begin mortising the workpiece when the
mortising chain has achieved its full speed.
- Examine the workpiece for foreign objects. Never
attempt to stem into metal objects, such as nails.

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- Keep a firm hold on the machine already before
switching it on. The mortising chain must stand
unobstructed while doing so. Apply the machine for
the mortising operation with running mortising
chain. Pay attention to a secure footing.
- Always lead the connecting cable away from the
machine to the rear while mortising.
- Match the feed speed during mortising to the
material thickness. Mortising too quickly leads to
motor overload, to unclean mortises and to the
mortising chain blunting quickly.
- Only remove the machine from the workpiece if it
has come to a standstill.
- Do not reach into the chip ejector and the
unprotected area of the mortising chain while the
machine is running.
- Before switching on the machine for freehand
milling, pay attention that the cross fence is
fastened and rests against the workpiece. Milling
must not start without cross fence!
- Only use the machine outdoors or in well ventilated
rooms.
- Wear a dust mask during machine operation.
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.
- Wear protective gloves for all maintenance and
repair work.
4Setting / Adjustment
4.1 Mains connection
Prior to commissioning make sure that the mains
voltage complies with the operating voltage stated on
the machine's rating plate.
4.2 Installation mortising chain set
Danger
Pull the power plug during all
service work.
•Lightly screw on the guide rail with the cylinder
head bolt. Pay attention that the guide rail rests
planely in the guide on the gearbox case and
possibly unscrew the threaded pin 14 (Fig. 1).
•The installation of mortising chain and chain
wheel is carried out as described under 4.3 and
4.4.
4.3 Mortising chain change
Danger!
Pull the power plug during all
service work.
Pay attention that the mortising chain to be clamped
has been well sharpened as this is the basic
requirement for correct mortising.
Proceed as follows to replace the mortising chain:
•First slacken the mortising chain by means of
the threaded pin 14 (Fig. 1).
•Remove the chain guard 11 (Fig. 2) by
simultaneously unfastening the two knurled
screws.
•Unfasten the cylinder head bolt 16.
•Unfasten and remove the countersunk bolt in
the transmission shaft.
•Remove the chain wheel, mortising chain and
guide rail together.
•For installation, proceed in reverse order.
•Refit the new mortising chain together with the
chain wheel and the guide rail and pay attention
that the cutting teeth are running in working
direction (see arrow on the chain guard 11 (Fig.
2)).
•Fasten the countersunk bolt in the transmission
shaft.
•Lightly tighten the cylinder head bolt 16 and
clamp the mortising chain with the threaded pin
14 (Fig. 1). The correct chain tension has been
achieved if the mortising chain can be lifted
approx. 6 mm (1/4 in.) in the middle of the guide
rail.
•Securely retighten the cylinder head bolt 16
(Fig. 2) after completion of the adjustment work.
•Refit the chain guard 11!

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4.4 Chain wheel change
Danger
Pull the power plug during all
service work.
•During a chain wheel change, the countersunk
screw in the gear shaft must be unscrewed with
the Allen key fastened on the machine by
knocking lightly against the key.
•For installation, proceed in reverse order. Push
the new chain wheel onto the gear shaft such
that the chain wheel groove gears into the
straight pin, which is pushed crossways through
the gear shaft.
5Operation
5.1 Initial operation
Personnel entrusted to work with the machine must
be made aware of the operating instructions, calling
particular attention to the chapter "Safety
instructions".
5.2 Switching on and off
Danger
Pay attention that the mortising
chain can be moved freely.
Lead the connecting cable away to
the rear.
Hold onto the machine with both
hands.
Only switch on the machine if the
mortising chain has no contact with
the workpiece.
•Switching on: First unlock the switch-on lock to
the front by pressing the locking lever 4 (Fig. 2).
Then actuate the control lever 3. As this is a
switch without locking device, the machine will
only run for as long as this switch is pressed.
•Switching off: Release control lever 3. The
switch-on lock automatically takes effect again
and secures the machine against accidental
switch-on.
Switch-on procedures create a
temporary reduction in voltage. In
case of unfavourable grid
conditions, this may lead to the
impairment of other devices.
In case of grid impedances smaller
than 0.27 Ohm, no interferences
are to be expected.
5.3 Cross fence setting
The distance between mortise and collar side is
steplessly variable from 8 to 150 mm (5/16 to 5 7/8
in.) with the crossfeed stop 6 (Fig. 2).
•Release the clamping lever 8 and set the
distance on scale 7. Note the reading edge
depending on the hole width 30, 35 or 40 mm (1
3/16, 1 3/8 or 1 9/16 in.)!
•Securely retighten the clamping lever 8
afterwards. The clamping lever is adjustable and
can be brought into any desired clamping
position by lifting it.
5.4 Mortising depth adjustment
The mortise depth is continuously variable.
•Release clamping lever 10 (Fig. 2) and set the
depth stop 9 to depth using a yard stick.
•Tighten clamping lever 10 (adjustable as 8) - do
not place in mortising direction! The mortising
depth depends on the mortising chain set used.
5.5 Operating method
To start mortising, hold the machine by its two
handles 1 and 2 (Fig. 2) and guide it - the crossfeed
stop 6 must rest against the wood. First mortise the
start and end of the mortise and then the rest. Mortise
with even pressure and infeed. The mortising chain
should be cleaned and lubricated in a low viscosity oil
bath after two hours of operation.
5.6 Mortising recesses
For this, two wooden ledges can be screwed on at
the drill holes Ø 4.5 mm (11/64 in.) on the crossfeed
stop 6 (Fig. 2) (see Fig. 4).

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6Service 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.
6.1 Mortising chains
The mortising chain used on the machine should be
cleaned and lubricated in a low viscosity oil bath after
two hours of operation. To do so, dismantle the
mortising chain (see chapter 4.3).
Replace the blunt mortising chains or have them
reground at a MAFELL customer service station or by
a suitable sharpening service.
6.2 Storage
Clean the machine thoroughly if the machine is not
used for a longer period of time. Spray blank metal
parts with a rust-proofing agent.
7Troubleshooting
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.
Defect
Cause
Elimination
Machine cannot be switched on
No mains voltage
Check power supply
Carbon brushes worn
Take the machine to a MAFELL
customer service shop
Chip ejection blocked
Wood is too damp

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8Optional accessories
- Guide support stand FG 150
Order No. 200980
- Slot mortising device SG 230
Order No. 200990
- Slot mortising device SG 400
Order No. 201000
- Slot mortising device SG 500
Order No. 201005
- Clamping device (for SG 400)
Order No. 039602
- Guide rail, cpl. 28x40x100
Order No. 091010
- Guide rail, cpl. 28x40x150
Order No. 091011
- Guide rail, cpl. 28x30/35x100
Order No. 091012
- Guide rail, cpl. 28x30/35x150
Order No. 091013
- Guide rail, cpl. 30x30/35x100
Order No. 091014
- Guide rail, cpl. 28x1.5x150
Order No. 091016
- Guide rail, cpl. 28x2x150
Order No. 091017
- Mortising chain 28x35/40/50x100
Order No. 091224
- Mortising chain 28x35/40x100
Order No. 091230
- Mortising chain 28x35/40x150
Order No. 091234
- Spare links with rivets 28 mm
Order No. 091279
- Chain wheel 28x35/40
Order No. 091683
9Exploded drawing and spare parts list
The corresponding information in respect of spare parts can be found on our homepage: www.mafell.com
Notes for after-sales service:
If a LS 103 Ec (with Cuprex motor) is to be mounted on an existing slot mortising device SG 400 or SG 500 at
the customer's (up to year of manufacture 2006), the pinion cpl. (pos. 2), item No 200842 on the slot mortising
device must be replaced by pinion cpl. 204740.
The handle on the pinion cpl. 204740 can be detached by means of the Allen key SW 4 which is included as
accessory with the LS 103 Ec and used to attach the LS 103 Ec on the SG 400 / SG 500.