Mafell MKS 165 Ec User manual

MKS 165 Ec
070551.0916/q
Handkreissäge Originalbetriebsanleitung 5
Portable Circular Saw Original operating instructions 15
Scie circulaire portative Traduction de la notice d'emploi originale 24
Sega circolare portatile Istruzioni per l'uso originali 34
Handcirkelzaag Originele gebruiksaanwijzing 44
Sierra circular manual Manual de instrucciones original 53
Käsisirkkeli Alkuperäiskäyttöohje 63
Handcirkelsåg Originalbruksanvisning 72
Håndrundsav Original driftsvejledning 81
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.

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English
Table of Contents
1 Signs and symbols .........................................................................................................16
2 Product information ........................................................................................................ 16
2.1 Manufacturer´s data ....................................................................................................... 16
2.2 Machine identification.....................................................................................................16
2.3 Technical data ................................................................................................................17
2.4 Noise emission specifications ........................................................................................17
2.5 Vibration specifications...................................................................................................17
2.6 Scope of supply..............................................................................................................17
2.7 Safety devices ................................................................................................................18
2.8 Use according to intended purpose................................................................................ 18
2.9 Residual risks ................................................................................................................. 18
3 Safety instructions .......................................................................................................... 18
4 Setting / Adjustment ....................................................................................................... 20
4.1 Mains connection ...........................................................................................................20
4.2 Chip extraction ............................................................................................................... 20
4.3 Saw blade selection .......................................................................................................20
4.4 Replacing the saw blade ................................................................................................20
4.5 Riving knife / splitter ....................................................................................................... 20
5 Operation........................................................................................................................ 20
5.1 Initial operation ...............................................................................................................20
5.2 Switching on and off ....................................................................................................... 21
5.3 Cutting depth adjustment ............................................................................................... 21
5.4 Setting for bevel cuts...................................................................................................... 21
5.5 Sawing according to tracings ......................................................................................... 21
5.6 Sawing with parallel guide fence .................................................................................... 21
6 Service and maintenance...............................................................................................22
6.1 Storage........................................................................................................................... 22
7 Troubleshooting..............................................................................................................22
8 Optional accessories ...................................................................................................... 23
9 Exploded drawing and spare parts list ........................................................................... 23

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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. 924501, 924520, 924522 or 924525
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
Universal motor, radio and TV interference
suppressed
230 V~, 50 Hz 120 V~, 60 Hz
Power input (nominal load) 2800 W 2500 W
Current at nominal load 15.2 A 23.5 A
Saw blade speed while idling 1500 - 1800 min-1
Saw blade speed at normal load 1400 - 1700 min-1
Cutting depth 85 - 165 mm
Maximum cutting depth 0°/30°/45° 143/116.5/82.5 mm
Tilting saw unit up to 60°
Saw blade diameter max/min 410/377 mm
Saw blade body thickness 2.5 mm (0.098 in.)
Tool cutting width 4.2 mm
Saw blade mounting hole 30 mm (1.18 in.)
Hose connector diameter 58 mm (2.28 in.)
Weight without mains cable, with parallel guide fence 15.3 kg (9.0 lbs)
Dimensions (W x L x H) 460 x 710 x 450 mm
2.4 Noise emission specifications
Noise emission values determined according to EN 60745-1 and EN 60745-2-5:
Sound power level Workplace-related emission value
Idling 103 dB (A) 92 dB (A)
Machining 111 dB (A) 100 dB (A)
The noise measurement was recorded using the saw blade included in the standard equipment.
The values stated do not take into consideration any possible series variances and are not suitable for
determining the rating levels, as these fluctuate in dependence on the time in service, the respective type of
machining and the environmental influences. The noise rating level can therefore only be determined on an
individual basis at the machine user's position.
2.5 Vibration specifications
The typical hand-arm vibration is less than 2.5 m/s2.
2.6 Scope of supply
Portable circular saw MKS 165 Ec complete with:
1 carbide-tipped circular saw blade Ø 410 mm (6 1/8 in.), 28 teeth
1 riving knife / splitter (thickness 2.5 mm / 3/32 in.)
1 hose connector
1 parallel guide fence
1 service tool in bracket on the machine
1 operating manual
1 folder “Safety Instructions”

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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:
-Upper stationary saw guard
-Lower retractable saw guard
-Large base plate
-Handles
-Riving knife / splitter
-Index mechanism and brake
-Hose connector
2.8 Use according to intended purpose
The portable circular saw is exclusively suitable for
longitudinal and cross cutting of solid wood.
Panel materials such as chip board, core board and
medium density fibre board 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.
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 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.
-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.
-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.

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Do not use:
-Cracked and misshapen 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 with a basic body with a thickness
greater than, or a cutting width (setting) less than,
the thickness of the riving knife / splitter.
-Saw blades which are not suitable for the saw
blade's idling speed.
Instructions on the use of personal protective
equipment:
-Always wear ear protectors during work.
-Always where a dust mark during work.
Instructions on operation:
-Do not reach with your hands into the sawing area
and do not touch the saw blade. With your other
hand, support the supplementary handle or the
motor casing.
-Do not reach under the workpiece.
-Adapt the cutting depth to the workpiece thickness.
-Never support the workpiece in your hand or over
your leg. Secure the workpiece against a sturdy
support.
-Only hold the device by its isolated handle
surfaces when carrying out work during which the
cutting tool could hit hidden power cables or its
own connection cable.
-Always use a limit stop or a straight edge guide for
longitudinal cutting.
-Always use correctly sized saw blades with
matching receiving bore (e.g. star-shaped or
round).
-Never use damaged or incorrect saw blade
washers or screws.
-Hold the saw with both hands and bring your arms
into a position where you are able to resist the
backlash forces. Always keep to the side of the
saw blade. Never bring the saw blade in line with
your body.
-If the saw blade gets jammed or sawing is
interrupted for some other reason, release the
on/off switch and keep the saw steady in the
material, until the saw blade has come to a
complete standstill. Never try to remove the saw
from the workpiece or to pull it backwards while the
saw blade is still moving or while a backlash could
occur.
-If you would like to restart a saw that is stuck in the
workpiece, centre the saw blade in the saw slit and
check whether the saw teeth are stuck in the
workpiece.
-Support large plates to reduce the risk of backlash
caused by a jammed saw blade.
-Do not use any blunt or damaged saw blades.
-Before starting to saw, tighten the cutting depth
and cutting angle adjustments.
-Be especially careful when making a “plunge cut“
into a concealed area, e.g. into an existing wall.
-Prior to every use, check whether the lower saw
guard is closing properly. Do not use the saw if the
lower saw guard is not freely movable and does
not close immediately. Never clamp or tie down the
lower saw guard in an open position.
-Check the function of the spring for the lower saw
guard. Have the device serviced if lower saw guard
and spring do not work properly.
-Only manually open the lower saw guard for
special cuts, such as “plunge and angle cuts“.
Open the lower saw guard using the retracting
lever and release the lever as soon as the saw
blade has penetrated the workpiece.
-Do not place the saw on the work bench or on the
floor without the lower saw guard covering the saw
blade.
-Use the saw blade that matches the riving
knife/splitter
-Adjust the riving knife / splitter as described in the
operating instructions.
-Always use the riving knife / splitter except for
“plunge cuts“.
-For the riving knife / splitter to function, it has to be
located in the saw slit.
-Never operate the saw with a bent riving knife /
splitter.
-Examine the workpiece for foreign objects. Never
attempt to cut into nails or other metal objects.

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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.
4 Setting / 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 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 inside diameter of hose connector 6 (Fig. 1) is 58
mm (2 9/32 in.).
4.3 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
hard wood:
-TCT circular saw blade Ø 410 x 4.2 x 30 mm (16
1/8 x 11/64 in. x 30 mm), 28 teeth
For cuts especially along the grain in soft or hard
wood:
-TCT circular saw blade Ø 410 x 4.2 x 30 mm (16
1/8 x 11/64 in. x 30 mm), 20 teeth
4.4 Replacing the saw blade
Danger
Pull the power plug during all
service work.
Proceed as follows to replace the saw blade:
Press the stop lever 15 (Fig. 2) to lock the saw
blade.
Place the hexagon head socket wrench that is
available in a bracket on the machine into the
flange screw 4 (Fig. 1) and turn it until the stop
lever has engaged completely. Turn the wrench
counter clockwise to release the flange screw.
Remove the screw and the front clamping flange
5. After opening the rectractable saw guard 1,
you can now remove the saw blade by lifting it
to the front and then pulling it in a downward
direction.
Before mounting the new saw blade, both
clamping flanges must be checked for adhering
parts and cleaned. Pay attention to the sense of
rotation when inserting the saw blade. The saw
blade teeth must point in the same direction as
the arrow on the upper saw guard. Afterwards,
mount the clamping flange, attach the flange
screw and tighten it by clockwise turning. In
doing so, the stop lever can be used in the
same way as when the screw was released.
Do not press the locking bolt 15
(Fig. 2) with the machine running!
The machine may get damaged.
4.5 Riving knife / splitter
Danger
Pull the power plug during all
service work.
The riving knife / splitter 2 (Fig. 1) prevents the saw
blade from jamming during longitudinal cutting. The
correct distance to the saw blade is shown in Fig. 3.
For adjustment, unfasten the two cylinder-head
screws 3 (Fig. 1) with the hexagon head socket
wrench supplied, adjust the riving knife / splitter
by moving it accordingly in its longitudinal slot
and afterwards retighten the two cylinder-head
screws.
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".

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5.2 Switching on and off
Switching on: First of all, unlock the switch-on
lock by pressing the locking lever 8 (Fig. 4).
Then, keeping the locking lever depressed,
activate the gearshift lever 7.
As this is a switch without locking device, the
machine will only run for as long as this gearshift
lever is pressed.
The built-in electronic system provides for jerk-free
acceleration when the machine is switched on and
under load readjusts the speed to the fixed setting.
In addition, this electronic system adjusts the motor
down in case of overload, i.e. the saw blade will stop.
Switch the machine off then. Then switch the
machine on again and continue sawing at a reduced
feed speed.
WIth the setting wheel 22 (Fig. 4) you can steplessly
adjust the saw speed between 1400 and 1700 rpm.
Switching off: To switch off, release the switch
trigger 7. The built-in automatic brake limits the
saw blade slowing time to approx. 5 s. The
switch-on lock automatically takes effect again
and secures the portable circular saw against
accidental switch-on.
5.3 Cutting depth adjustment
The cutting depth is continuously variable between 85
and 165 mm (3 3/8 and 6 1/2 in.).
Proceed as follows to adjust it:
First of all, release the clamping lever 10 (Fig. 5)
by turning it counter clockwise.
You can now adjust the cutting depth by turning
the handle 9.
The set depth can be read off the scale ring 21
(Fig. 5). The inscription on the gearbox case
serves as indicator in this regard.
After adjusting, tighten the clamping lever again.
Always set the cutting depth
approx. 2 to 5 mm (1/16 to 3/16 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 60°.
Bring the machine into a stable position and
support it such that it is possible to tilt the saw
unit.
Then release the two wing screws 16 (Fig. 2
and Fig. 4), tilt the unit to the desired angle
shown on the indicator 17 (Fig. 2) on scale 18 at
the segment for tilting.
Afterwards, retighten both wing screws 16 (Fig.
2 and Fig. 4).
5.5 Sawing according to tracings
The base plate is on the inside equipped with a
tracing edge that applies both to straight cuts and for
all angles of inclination. 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 (arrow, Fig. 5).
For sawing, hold the machine by both its
handles 11 (Fig. 4) and 12 (Fig. 2) and place the
front part of the base plate onto the workpiece.
To facilitate the first cut, the retractable saw
guard 1 (Fig. 1) can be opened by pressing the
lever 13 (Fig. 5) that is arranged directly next to
the front handle.
When this lever is released, the saw guard closes
automatically.
Switch on the portable circular saw (see chapter
5.2) and slide the machine evenly forward in the
direction of the cut.
Once you have executed the cut, immediately
switch off the saw by releasing the gearshift
lever 7 (Fig. 4).
5.6 Sawing with parallel guide fence
The portable circular saw is equipped with a parallel
guide fence on both sides, so that it is possible to saw
on both sides of the machine parallel to an already
existing edge without retooling. The cutting range on
the right-hand side amounts to 140 mm (5 1/2 in.) and
on the left-hand side to 320 mm (12 5/8 in.).
In order to adjust the cutting width, unscrew the
wing screws 14 (Fig. 4) and move the guide
fence accordingly. Afterwards, retighten the
wing screws 14.

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In addition, it is possible to turn the guide fence plate
20 (Fig. 2) of the parallel guide fence by 90°. With
that it is possible to use the guide fence surface both
above and below the base plate. If a straight
workpiece edge is already available and if a parallel
cut is to be made to this, the guide fence plate 20 is
turned down.
If there is no straight workpiece edge, the guide fence
plate is turned up to carry out a straight cut.
Now the machine can be guided either along a lathe
fastened on the workpiece or along the guide rail that
is available as optional accessory.
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.
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.
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 mains back-up fusesMachine stops while cutting is in
process Machine overloaded Reduce feed speed
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 guide fence
Saw blade jams as the machine is
advanced
Uneven workpiece surface Straighten the surface
Burn marks on the cut surfaces The saw blade used is unsuitable
for the task or blunt
Replace saw blade
Wood is too dampChip ejection blocked
Extended operation without
exhaustion
Connect to an external exhaustion,
e.g. portable dust extractor

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8 Optional accessories
-Guide rail, one-piece, cpl. 3 m (9.85 ft) long Order No. 200672
-Guide rail, two-piece, cpl. 3 m (9.85 ft) long Order No. 037037
-Guide rail – extension 1.5 m (4.9 ft) long Order No. 036553
-Adapters (pair) for parallel limit stop for hooking into the guide rail Order No. 037195
-Saw blade - TCT Ø 410 x 4.2 x 30 mm (16 1/8 x 11/64 in. x 30 mm), 20
teeth (rip cut)
Order No. 092522
-Saw blade - TCT Ø 410 x 4.2 x 30 mm (16 1/8 x 11/64 in. x 30 mm), 28
teeth (rip / cross cut)
Order No. 092525
-Guide rail F80, 800 mm (2.6 ft) long Order No. 204380
-Guide rail F110, 1100 mm (3.6 ft) long Order No. 204381
-Guide rail F160, 1600 mm (5.25 ft) long Order No. 204365
-Guide rail F210, 2100 mm (6.9 ft) long Order No. 204382
-Guide rail F310, 3100 mm (10.2 ft) long Order No. 204383
-Sliding bevel segment F-WA Order No. 205357
-Accessories for guide rail:
-Screw clamp F-SZ100MM (2 Qty.)
-Connecting piece F-VS
-Rail bag F160
Order No. 205399
Order No. 204363
Order No. 204626
-Rail bag kit F80/160 consisting of: F80 + F160 + connecting piece + 2
screw clamps + rail bag
Order No. 204748
-Rail bag kit F80/160 with sliding bevel segment consisting of: F80 + F160
+ connecting piece + sliding bevel segment + 2 screw clamps + rail bag
Order No. 204749
-Rail bag kit F160/160 consisting of: 2 x F160 + connecting piece + 2
screw clamps + rail bag
Order No. 204805
9 Exploded drawing and spare parts list
The corresponding information in respect of spare parts can be found on our homepage: www.mafell.com