Mafell ZSX-TWIN Ec User manual

ZSX TWIN-Ec
170325.0415/c
Zimmerei-Kettensäge Originalbetriebsanleitung 5
Carpenter's chain saw Original operating instructions 18
Scie à chaîne de charpente Traduction de la notice d'emploi originale 31
Sega a catena per carpenteria Istruzioni per l'uso originali 44
Timmermanskettingzaag Originele gebruiksaanwijzing 57
Sierra de cadena para
carpinteros
Manual de instrucciones original 70
Kirvesmies-ketjusaha Alkuperäiskäyttöohje 83
Snickeri-kedjesåg Originalbruksanvisning 95
Tømrer-kædesav Original driftsvejledning 107
ACHTUNG!
Diese Betriebsanleitung enthält Hinweise, die für das sichere Arbeiten mit dieser Maschine wichtig sind.
Lesen Sie deshalb unbedingt diese Betriebsanleitung.
WARNING!
These operating instructions contain important information on safe working practices for this machine.
It is therefore essential that you read these operating instructions carefully.
ATTENTION !
Cette notice d'emploi contenant des indications importantes pour la sécurité du travail avec cette machine,
veuillez donc la lire impérativement.
ATTENZIONE!
Le presenti istruzioni per l’uso contengono avvertenze importanti per lavorare con sicurezza con questa macchina.
Per questo motivo è assolutamente necessario leggere le presenti istruzioni per l’uso con la dovuta accuratezza.
ATTENTIE!
Deze gebruiksaanwijzing omvat instructies die voor het veilige werken met deze machine belangrijk zijn.
Lees vandaar in ieder geval deze gebruiksaanwijzing.
¡ATENCIÓN!
Lea atentamente este manual de instrucciones, que contiene la información necesaria para garantizar la seguridad en el
trabajo con esta máquina.
HUOMIO!
Tämä käyttöohje sisältää ohjeita, jotka ovat tärkeitä koneen turvallisen käytön kannalta.
Lue käyttöohje sen vuoksi huolellisesti!
OBSERVERA!
Denna bruksanvisning innehåller anvisningar, viktiga för säkert arbete med denna maskin.
Läs därför denna bruksanvisning noga!
GIV AGT!
Denne driftsvejledning indeholder vigtige henvisninger om sikkerheden ved brug af maskinen.
Læs driftsvejledningen omhyggeligt.

-18-
English
Table of Contents
1 Signs and symbols .........................................................................................................19
2 Product information ........................................................................................................19
2.1 Manufacturer´s data ....................................................................................................... 19
2.2 Machine identification.....................................................................................................19
2.3 Technical data................................................................................................................20
2.4 Noise emission specifications ........................................................................................ 21
2.5 Vibration specifications...................................................................................................21
2.6 Scope of supply..............................................................................................................21
2.7 Safety devices................................................................................................................21
2.8 Use according to intended purpose................................................................................ 21
2.9 Residual risks ................................................................................................................. 22
3 Safety instructions .......................................................................................................... 22
4 Setting / Adjustment .......................................................................................................23
4.1 Mains connection ........................................................................................................... 23
4.2 Saw chain change..........................................................................................................24
4.3 Chain tension .................................................................................................................24
4.4 Chain lubrication.............................................................................................................25
4.5 Setting the parallel stop..................................................................................................25
4.6 Setting for angle cuts (bevel and jack rafter cuts) ..........................................................26
4.7 Setting the glider ............................................................................................................26
5 Operation........................................................................................................................ 26
5.1 Initial operation...............................................................................................................26
5.2 Switching on and off....................................................................................................... 26
5.3 Work instructions............................................................................................................ 26
5.4 Large cutting lengths...................................................................................................... 27
6 Service and maintenance...............................................................................................27
6.1 Machine.......................................................................................................................... 27
6.2 Guide rail of the chain set............................................................................................... 27
6.3 Chain wheel....................................................................................................................27
6.4 General sharpening information.....................................................................................27
6.5 Storage........................................................................................................................... 28
7 Troubleshooting.............................................................................................................. 28
8 Optional accessories ...................................................................................................... 29
9 Exploded drawing and spare parts list ........................................................................... 30

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1 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.
2 Product information
for machines with product no. 961601, 961625
2.1 Manufacturer´s data
MAFELL AG, Postfach 1180, D-78720 Oberndorf / Neckar, Phone [phone], Fax [phone]-
218
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
Tool (saw chain type) 400 HM
Number of drive links 40
Chain pitch 18 mm (23/32 in.)
Cutting width 6.8 mm (17/64 in.)
Cutting speed at normal load 13.5 – 16.4 m/s
(44.3 – 53.8 ft/s)
Swivel range on both sides 60° / 15°
Cutting depth
at 0° 400 mm (15 3/4
in.)
at 15° 386 mm (15 3/16
in.)
at 30° 346 mm (13 5/8
in.)
at 45° 282 mm (11 7/64
in.)
at 60° 199 mm (7 27/32
in.)
Chain set swivelling to the rear by 10°
Machine dimensions
Width x length x height 450 x 632 x 800
mm (17 11/16 x 24
7/8 x 31 1/2 in.)
Base plate 300 x 506 mm (11
13/16 x 19 15/16
in.)
Width without limit stop 415 mm (16 21/64
in.)
Height without tool and riving knife/splitter 312 mm (12 9/32
in.)
Weight without mains cable 24.2 kg (53.35 lbs)
Universal motor, radio and TV
interference suppressed
230 V~, 50 Hz
Power input (nominal load) 2x3000 W
Current at nominal load 2x15.9 A
Idling speed 21000 rpm
Speed of the chain pinion Idling
Normal load
3600 rpm
3400 rpm

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2.4 Noise emission specifications
The noise emission values ware determined according to EN 60745-1 with the following deviation: The
workpiece used was a fir wood beam as sawn with a thickness of 100 mm. The emission values amount to:
Sound power level Workplace-related emission value
Idling 111 dB (A) 100 dB (A)
Machining 108 dB (A) 97 dB (A)
The values stated are emission levels. Although there is a correlation between emission and imission 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 source 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.
2.5 Vibration specifications
The typically assessed acceleration is 3.2 m/s2.
2.6 Scope of supply
Carpenter's chain saw ZSX TWIN-Ec complete with:
Guide rail for saw chains Special 400
Riving knife/splitter 400
Saw chains 1 x special 400 HM
1 x special 400 HM longitudinal
cut
18 mm
18 mm
1 connecting cable
1 parallel guide fence
1 glider
2 operating tool
1 trolley
1 operating manual
1 folder “Safety Instructions”
2.7 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:
-protective equipment above the base plate
-bottom deflection with guard plate
-special design of the saw chain
-riving knife/splitter
-large base plate and parallel stop
-handles
-index mechanism with lock and brake
2.8 Use according to intended purpose
The carpenter's chain saw is exclusively suited for
longitudinal and cross cutting of solid wood up to a

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maximum thickness of 400 mm (15 3/4 in.)
exclusively using the special saw chain provided by
MAFELL, with the machine having to rest on the
workpiece with its base plate 3 (Fig. 1). The machine
may be operated by one person only. At the same
time, the machine must be held and guided by its two
handles 1 and 2 provided for that purpose.
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.
2.9 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 running saw chain below the base
plate.
-Touching the standing saw chain below the base
plate.
-Machine backlash if the blade gets stuck in the
workpiece.
-Tearing of the saw chain.
-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.
3 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.
-Do not carry the machine by its cable and do not
use the cable to pull the plug out of the socket
outlet.
-Pay attention that the cable is protected against oil
and heat and is not pulled across sharp edges.
-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.
-Always check before beginning work, whether the
protection and work equipment is safely attached
and not damaged. Damaged protection devices
and parts must be repaired or replaced
appropriately.
-Consider environmental influences. Do not expose
the machine to rain and avoid working in a damp
or wet environment as well as near to combustible
liquids or gases.
-Store the device in a dry, locked place outside the
reach of children.
Instructions on the use of personal protective
equipment:
-Always wear ear protectors during work.
-Always where a dust mark during work.
-Always wear closely fitting work clothes and take
off rings, wristbands, and watches.
Instructions on operation:
-Provide for an unobstructed and slip-proof location
with adequate lighting.
-The power plug must be pulled before replacing
tools, making adjustments and repairing
malfunctions (this also comprises removing
jammed splinters).

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-Do not work on workpieces which are too small or
too large for the capability of the machine.
-Whenever possible, secure the workpiece against
slipping, e.g. with screw clamps.
-Only use original MAFELL saw chains.
Commercial saw chains are not suitable for this
machine. After every chain change, check the
correct chain tension.
-The riving knife/splitter 4 (Fig. 1) including the
guard plate for the bottom chain deflection 6 may
not be removed.
-The machine is a one-man tool and may only be
used for work during which the base plate 3 serves
as workplate.
-Prior to carrying out any work, check whether the
tank contains oil for the chain lubrication and
whether the chain lubrication is working (see
section 4.4).
-Keep a firm hold on the machine already before
switching it on and support it. At the same time, rail
and chain must stand unobstructed. Only begin
cutting the workpiece when the saw chain has
achieved its full speed. Pay attention to a secure
footing.
-The switch may not be wedged in ON position.
-Never reach below the base plate or into the chip
ejector during sawing.
-Never transport the machine with running saw
chain and pay attention that, except for the
workpiece, the running chain does not come in
contact with adjacent objects.
-Never remove cover 12 (Fig. 1) covering the chain
pinion with the machine running and only for a tool
change and refit immediately afterwards.
-The machine can be connected to an extraction
with a diameter of 54 mm (2 1/8 in.) (outside) or 49
mm (1 15/16 in.) (inside). When working without
extraction, work may only be carried out outdoors
or in adequately ventilated rooms.
-Once adopted, never change a cutting direction by
force. The saw must be guided such that the
pressure does not bring the chain to a stop.
-Examine the workpiece for foreign objects. Never
attempt to cut into nails or other metal objects.
-Always lead the connecting cable away from the
machine to the rear while sawing.
-Immediately pull the power plug in case of
damaged or severed connecting cables.
-Match the feed speed during sawing to the
material thickness. Feeding too fast results in an
overload of the motor, rough saw cuts and faster
blunting of the saw chain.
-Only remove the machine from the workpiece if the
saw chain has come to a standstill.
Instructions on service and maintenance:
-Regular cleaning of the machine, in particular the
setting mechanisms for tilting the guides for the
parallel stop and the enclosure of the top and
bottom chain deflection, constitutes an important
safety factor. Pull the plug before starting this
work.
-Only original MAFELL spare parts and accessories
may be used. Otherwise, the manufacturer will not
accept any warranty claims and cannot be held
liable.
4 Setting / Adjustment
4.1 Mains connection
Prior to commissioning make sure that the supply
voltage complies with the operating voltage stated on
the machine's rating plate.
The machine must be connected to the three phase
network. Because of the machine's internal wiring,
each of the two motors is supplied with 230 V~.
Ensure that the assignment of the socket outlet is
carried out according to standard. A wrong
assignment may lead to destruction of the electronic
system. The machine is totally insulated, therefore
the earth contact inside the plug was removed.

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4.2 Saw chain change
Danger
It is imperative to pull the power
plug before replacing the saw
chain.
Risk of injury even if the saw chain
is standing still.
Proceed as follows to replace the saw chain:
Unfasten cylinder head bolt 13 using
combination screw driver 11 enclosed in the
supply and fastened on cover 12 (Fig. 1) and
fold down the cover.
Open the spring-loaded bottom guard flap 15
(Fig. 2) downwards and fasten it with the cover
in open position.
Unscrew the hexagon socket head cap screw
18 (Fig. 2) and remove the Intermediate cover
19 including the oil tank.
Unfasten the fastening screw 5 (Fig. 1) for the
lower chain deflection protection and fold down
the guard plate 6.
Release the chain tension by turning the
tensioning screw 20 (Fig. 3) to the left by means
of combination screw driver 11.
Pull off the guide rail 21 including the saw chain
and chain wheel 22 to the front and remove the
chain.
Place a new or freshly sharpened saw chain
onto the guide rail and the chain wheel. In the
process, pay attention that the tooth cutting
edges of the chain point in direction of the
marking 24 for the direction of travel and that
the chain fastening bolt 23 engages in the hole
in the guide rail provided for that purpose.
Using combination screw driver 11 (Fig. 7), twist
the gear shaft such that chain wheel 22 with the
fitted saw chain easily engages in the driving
gear teeth.
Caution!
After installation of the saw chain
set, immediately pull off
combination screw driver 11.
Slide open the intermediate cover 19 and
slightly tighten the hexagon socket head cap
screw 18. Using combination screw driver 11,
turn the clamping screw 20 (Fig. 3) that can be
reached through the hole in the intermediate
cover clockwise until the correct chain tension
has been achieved (see section 4.3).
Tighten the hexagon socket head cap screw 18.
Fold up the protection for the bottom chain
deflection and tighten it with screw 5 (Fig. 1).
Unlock the bottom guard flap 15 (Fig. 2). Fold
up the cover 12 and tighten the cylinder head
bolt 13. Fasten combination screw driver 11 in
the brackets inside the cover.
If a new saw chain has been fitted, it must be run in in
idling mode for approx. 2 to 3 minutes. Pay attention
to adequate chain lubrication. After running-in, it may
be necessary to correct the chain tension.
4.3 Chain tension
For a safe operation of the machine and for the life
time of the entire chain set it is important that the
correct chain tension is set. This must therefore be
checked prior to start-up and once in a while during
operation. The chain tension is set correctly if in a
cold operating condition, the saw chain abuts on the
guide rail and can be manually lifted by 3 to 4 mm
(1/8 to 3/16 in.).
When heated to operating temperature, the saw chain
elongates and starts to sag. If the elongation is that
large that the chain links start to disengage from the
guide at the rail, the saw chain must be retensioned.
Danger
Pull the power plug during all
service work.
Proceed as follows to retension the saw chain:
Open the spring-loaded bottom guard flap 15
(Fig. 2) downwards. Using combination screw
driver 11 fastened on cover 12 (Fig. 1), slightly
release the hexagon socket head cap screw 18
(Fig. 2) through the bottom opening in cover 12
and screw 5 (Fig. 1).
Adjust the chain tensioning screw 20 through
the top opening in the cover (see Fig. 1) using
combination screw driver 11. Turning clockwise
means increasing and turning anti-clockwise
means decreasing the chain tension.

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Tighten the hexagon socket head cap screw 18.
Fold up the protection for the bottom chain
deflection and tighten it with screw 5 (Fig. 1).
If the saw chain is retensioned after it has heated up,
it is absolutely necessary to slacken it again once
sawing has been completed. Failure to do so would
cause very high shrinkage stresses due to the saw
chain contracting when cooling down to ambient
temperature, in particular if very low outside
temperatures are prevailing.
Until it has elongated, a new saw chain must be
retensioned more frequently than a saw chain that
has already been used for a longer period of time.
4.4 Chain lubrication
Correct lubrication of the saw chain is of major
importance for its life time. A dry running chain will
quickly damage the entire chain set irreparably.
Lubrication is adequate if a trail of oil is visible
between saw chain and guide rail.
It is therefore important to check the chain lubrication
function prior to the start of work and to check the oil
level in the lubricant tank. It may not drop below the
marking placed in cover 12 (Fig. 1) next to inspection
window 14. Only use biodegradable oil for the refill.
The oil tank filling quantity amounts to approx. 0.3
litres.
Danger
If any oil should get into your eyes
during refilling, immediately rinse
them with a copious amount of
water. Spilled oil must be absorbed
with commercial oil binders. Before
adjusting the chain lubrication pull
the power plug!
The flow rate of the built-in oil pump can be adjusted.
A normal dosing rate has been set at the factory,
which can be verified by the fact that an oil trace is
visible between saw chain and guide rail. However, if
necessary, the dosing rate can be changed. Proceed
as follows:
Unfasten cylinder head bolt 13 using
combination screw driver 11 enclosed in the
supply and fastened on cover 12 (Fig. 1) and
fold down the cover.
Open the spring-loaded bottom guard flap 15
(Fig. 2) downwards and fasten it with the cover
in open position.
Unscrew the hexagon socket head cap screw
18 (Fig. 2) and remove the Intermediate cover
19 including the oil tank.
Dosing screw 25 (Fig. 4) that is now accessible
at the rear of the intermediate cover can be
used to adjust the oil pump's flow rate. Turning
the screw clockwise increases the flow rate,
turning it anti-clockwise decreases the flow rate.
Refit the intermediate cover 19 (Fig. 2) and
tighten it with hexagon socket head cap screw
18.
Unlock the bottom guard flap 15 (Fig. 2). Fold
up the cover 12 (Fig. 1) and tighten the cylinder
head bolt 13. Fasten combination screw driver
11 in the brackets inside the cover.
Whether the flow rate now meets the
requirements can now be checked by briefly
switching on the machine.
4.5 Setting the parallel stop
The parallel stop 7 (Fig. 1) is used to execute parallel
cuts along the outside edge of the workpiece from a
cutting width of 175 mm (6 57/64 in.). For this
purpose, the narrow edge of the stop must point
downwards.
With adapter 32 (Fig. 12) and guide rail 33 (both
available as special accessories), the stop can be
used from a cutting width in excess of 190 mm (7
31/65 in.).
The stop can be used on both sides of the machine.
To adjust the cutting width or to use it on the other
side of the machine, the two wing screws 8 (Fig. 1)
are unfastened, the parallel stop is moved
accordingly and then the wing screws are retightened
well.
The base plate is equipped with reading edges at all
four slide-in positions on which the markings applied
to the guide rods of the parallel stop can be read off.
In this manner, the parallel stop can be set exactly
parallel to the chain set.
When using the parallel stop on the left-hand side of
the machine, the cutting width is the direct
measurement between the guide surface of the limit
stop and the tracing edge 26 (Fig. 6). This

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measurement is the same for all cutting angles! If the
parallel stop is used on the right-hand side of the
machine, the chain width must still be deducted from
this measure (6.8 mm for a vertical cut). However, in
this case it is recommended to determine the correct
setting by executing a trial cut. If the right-hand side
of the chain is used to saw at the marking, tracing
edges 27 graduated according to cutting angle apply
(Fig. 6).
4.6 Setting for angle cuts (bevel and jack rafter
cuts)
In order to carry out bevel cuts and in both directions,
to the right up to 60°, to the left up to 15°. To do so,
the machine is placed onto the trolley such that the
guide rail is free moving. After unfastening of the
handle 16 (Fig. 1) and deactivating the locking lever
by pulling and twisting the handle 9, the machine can
be tilted. The cutting angle can be read of the angle
scale 17.
If the locking lever is activated, this facilitates setting
the 0° and 45°- positions.
Depending on the set cutting angle, the maximum
cutting depths amount to:
260 HM 400 HM 400 Q
-at 60° 130 mm
(5 1/8 in.)
199 mm
(7 7/8 in.)
199 mm
(7 7/8 in.)
-at 45° 184 mm
(7 1/4 in.)
282 mm
(11 1/8 in.)
282 mm
(11 1/8 in.)
-at 30° 225 mm
(8 7/8 in.)
346 mm
(13 5/8 in.)
346 mm
(13 5/8 in.)
-at 15° 251 mm
(9 7/8 in.)
386 mm
(15 1/4 in.)
386 mm
(15 1/4 in.)
After setting the cutting angle, retighten handle 16.
4.7 Setting the glider
Use the glider 31 (Fig. 12) if the machine is used on
the guide rail F 80, 110, 160, 210, 310 to prevent it
from tilting to the right. If the machine is inclined, you
need to adjust the glider to the right.
5 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
Danger
Before switching on the machine,
pay attention that the guide rail and
the saw chain are unobstructed.
The workspace underneath the
workpiece must be free of
obstacles. Lead the connecting
cable away to the rear. Hold the
machine with both hands by the
handles provided for that purpose.
Switching on: First unlock the switch-on lock
by pressing the locking lever 10.1 (Fig. 1) to the
front. Then actuate the control lever 10. As this
is a switch without locking device, the machine
will only run for as long as this switch is
pressed.
The carpenter's chain saw ZSX TWIN-Ec is equipped
with an electronic speed control. The speed is set to
3600 rpm
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.
Switching off: To switch off, release the switch
trigger 10. The switch-on lock automatically
takes effect again and secures the carpenter's
chain saw against accidental switch-on.
5.3 Work instructions
Handling and layout of the carpenter's chain saw ZSX
TWIN-Ec corresponds to a portable circular saw. The
riving knife/splitter 4 prevents the saw chain from
jamming and the safeguard of the bottom chain
deflection a turning up of the machine. It is
particularly suited for cross cuts and longitudinal cuts
requiring a large cutting depth, in particular also for
joining laminated timber.
Before switching on, place the machine with its base
plate 3 such onto the workpiece that there is not yet
any contact between saw chain and workpiece. Hold
the machine by both handles 1 and 2 and after
switching on, slide evenly forwards without canting.
Therefore, if possible, always guide the machine with

-27-
the parallel stop either along the workpiece edge or
along a guide rail that is available as special
accessory (see section 4.5). The use of a guide rail
achieves a clearly higher cut quality.
5.4 Large cutting lengths
For large cutting lengths (e.g. several beams in a
row) the guide rail can be tilted to the rear by 10° (see
Fig. 5). This makes it easier to guide the machine
straight ahead, in particular at the transition from one
workpiece to the next.
Danger
Pull the power plug during all
service work.
For tilting, first of all the two set screws 28 (Fig. 5) are
unfastened with the enclosed operating tool and the
chain guide rail is swivelled up to the limit stop in the
direction of the rear handle. Then tighten the set
screws again.
6 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.
6.1 Machine
The machine must be regularly cleaned off deposited
dust. When doing so, you should clean the ventilation
openings on the motor with a vacuum cleaner.
Only use our special grease, order No. 049040 (1 kg
tin) for all greasing points.
The chain sets used on the machine should be
regularly deresinated, as clean tools improve the
quality of the cut. Deresination is carried out by
soaking the chain set in petroleum or a commercial
deresination agent for 24 hours.
6.2 Guide rail of the chain set
This guide rail must be maintained regularly. This
includes lubricating the chain deflection wheel and
deburring the rail.
Lubricating the carbide guide rail - see Fig. 8
Dismantle chain set (see section 4.2).
Clean lubrication hole.
Place guide rail onto a flat surface.
Press the mouthpiece of the grease gun tightly
into the lubrication hole and press until grease
emerges at the deflection. Use a good, acid-free
bearing grease for this purpose.
Refit the chain set (see section 4.2).
Deburring - see Fig. 9
Dismantle chain set (see section 4.2).
Remove chain from the guide rail.
Remove the burr using a flat file as shown in
Fig. 9.
Replace the chain and refit the chain set (see
section 4.2).
6.3 Chain wheel
The stress on chain wheel 22 (Fig. 3) is particularly
high. If it exhibits extremely visible grooves at the
individual teeth (approx. 0.5 mm / 1/64 in.) it must be
replaced without fail. MAFELL recommends to have
this work carried out by an authorised customer
service shop.
6.4 General sharpening information
Just as important as quality and care of the machine
are quality and care of the saw chain, guide rail and
chain pinion.
If the care of one of these «partners», which are
acting jointly during sawing, is neglected, the
consequences are frequently:
-Wear or destruction of other partners
-Lacking cutting performance
-Bad surface
-A possible safety risk

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Caution
Nails or adhering sand will damage
the saw chain. They must be
removed from the cut surface.
Saw chains for:
ZSX TWIN-Ec (Item No. 006968, 006971, 006972,
006974, 006977)
These chains can only be reground
at MAFELL via your appointed
dealer.
6.5 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.
7 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.
Defect Cause Elimination
No mains voltage Check power supply
Mains fuse defective Replace fuse
Machine cannot be switched on
Carbon brushes worn Take the machine to a MAFELL
customer service shop
Mains failure Check pre-fuseMachine switches off automatically
during idling or stops during
cutting Machine overloaded Reduce feed speed
Feed rate too fast Reduce feed speedSaw chain jams as the machine is
advanced Blunt saw chain Release the switch immediately.
Remove machine from the
workpiece and replace saw chain
or have it reground at an
appointed MAFELL dealer.
Only concerns item No. 006968,
006972 and 006977
Before regrinding, mind the
minimum length of the carbide
teeth see Fig. 11
Saw chain is running out or
increased effort necessary during
advancing
Blunt saw chain Replace saw chain or have it
reground at an appointed MAFELL
dealer
Chip ejection blocked Wood is too damp
Saw chain is coasting a long time
after it has been switched off
Automatic chain brake defective Take the machine to a MAFELL
customer service shop

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8 Optional accessories
-Guide rail 260 Order No. 204581
-Fine-cut saw chain - HM 260 Order No. 006968
-Driving star wheel Order No. 204584
-Splitting wedge 260 Order No. 204586
-Guide rail 400 Order No. 204582
-Fine-cut saw chain - HM 400 Order No. 006972
-longitudinal cut chain – HM 400 Order No. 006977
-Driving star wheel Order No. 204584
-Splitting wedge 400 Order No. 204587
-Guide rail 400 for 3/8“ Order No. 204583
-Saw chain - 3/8“ 400 cross and longitudinal cut Order No. 006974
-Driving star wheel 3/8“ Order No. 204585
-Splitting wedge 400 Order No. 204587

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-Guide rail F 80, 800 mm (2.62 ft) long Order No. 204380
-Guide rail F 110, 1100 mm (3.61 ft) long Order No. 204381
-Guide rail F 160, 1600 mm (5.25 ft) long Order No. 204365
-Guide rail F 210, 2100 mm (6.89 ft) long Order No. 204382
-Guide rail F 310, 3100 mm (10.17 ft) long Order No. 204383
-Rail connector F – VS Order No. 204363
-Rail bag 160 Order No. 204626
-Rail bags set 2x1.6 + F-VS + 2 x F-SZ Order No. 204805
-Rail bags set 1x0.8 + 1x1.6 + F-WA + F-VS Order No. 204749
-End caps F-EK Order No. 205400
-Adhesive profile F-HP 6.8 m Order No. 204376
-Splinter guard F-SS 3.5 m Order No. 204375
-Sliding bevel segment F-WA Order No. 205357
-Universal guide (shift rail) Order No. 202069
-Guide rail, one-part, complete 3 m (9.84 ft) long Order No. 200672
-Guide rail, two-part, complete 3 m (9.84 ft) long Order No. 037037
-Guide rail – extension 1.5 m (4.92 ft) long Order No. 036553
-Pair of adapters for parallel stop for hooking into the guide rail Order No. 037195
-Flat file Order No. 076058
-Push type grease gun Order No. 076158
9 Exploded drawing and spare parts list
The corresponding information in respect of spare parts can be found on our homepage: www.mafell.com