Mafell pss 3100 se Assembly instructions

PSS 3100 SE
170765.0122/a
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 35
Versión en español
Ver la página 68

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English
Table of contents
1Signs and symbols ........................................................................................................... 4
1.1 Identification of the device................................................................................................6
2Product specifications ......................................................................................................7
2.1 Technical data .................................................................................................................. 7
2.2 Scope of delivery.............................................................................................................. 8
2.3 Adjustment elements........................................................................................................8
3General safety .................................................................................................................. 9
3.1 Intended use..................................................................................................................... 9
3.2 Foreseeable misuse .........................................................................................................9
3.3 Safety instructions .......................................................................................................... 10
3.4 Specific safety rules .......................................................................................................11
3.5 Safety devices ................................................................................................................13
3.6 Residual risks ................................................................................................................. 14
4Setup / adjustment .........................................................................................................14
4.1 Mains connection ...........................................................................................................14
4.2 Routing of the connecting cable ..................................................................................... 14
4.3 Chip extraction ............................................................................................................... 15
4.4 Saw blade selection .......................................................................................................16
4.5 Changing the saw blade.................................................................................................16
4.6 Riving knife..................................................................................................................... 19
5Operation........................................................................................................................20
5.1 Startup............................................................................................................................20
5.2 Switching on ...................................................................................................................20
5.3 Rotational speed setting.................................................................................................20
5.4 Setting the feed speed ................................................................................................... 21
5.5 Switching off ...................................................................................................................21
5.6 Cutting depth setting ...................................................................................................... 22
5.7 Setting the cutting length................................................................................................ 22
5.8 Ripping ........................................................................................................................... 23
5.9 Plunge cuts..................................................................................................................... 25
5.10 Scoring ........................................................................................................................... 26
5.11 Guide rail extension........................................................................................................ 27
5.12 Working with special accessories................................................................................... 29
6Service and maintenance...............................................................................................30
6.1 Machine maintenance .................................................................................................... 30
6.2 Storage........................................................................................................................... 30
6.3 Transport ........................................................................................................................ 31
7Troubleshooting.............................................................................................................. 32
8Optional accessories ...................................................................................................... 34

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9Exploded view and spare parts list................................................................................. 34

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1Signs 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 dangerous situation that will cause serious or fatal
injuries.
Potentially dangerous situation that can cause serious or
fatal injuries.
Potentially dangerous situation that can cause light injuries.
Situation that can cause material damage on the machine
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

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2Product specifications
2.1 Technical data
Saw blade drive:
Universal motor
120 V~, 60 Hz
Power consumption (normal load)
1490 W
Current at normal load
13.5 A
Saw blade speed at no load
2600 to 5200 rpm
Saw blade speed at normal load
1700 to 3400 rpm
Cutting depth
0 to 45 mm [0 to 1.77 in]
Cutting length without extension
1300 mm [51.18 in]
Cutting length with extension
3100 mm [122 in]
Saw blade diameter max/min
160/149 mm [6.30/5.87 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]
Feed drive:
Permanent magnet DC motor
12 V
Power consumption (normal load)
32 W
Current at normal load
2.65 A
Feed rate without load
4 –20 m/min [13 - 65 ft/min]
Return speed
25 m/min [82 ft/min]
Overall system:
Weight without power cord, without extension
14 kg [30.86 lbs]
Weight of the guide rail extension
4.5 kg [9.92 lbs]
Total system weight without power cord
18.3 kg [40.35 lbs]
Working area with guide rail extension
3770 x 225 mm [148.43 x 8.86 in]
Dimensions (width x length x height)
without extension
340 x 1980 x 230 mm [13.39 x 77.95 x 9.05 in]

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2.2 Scope of delivery
Fig. 1: Scope of delivery
Components
A
Panel saw system
B
Allen key in bracket on the machine
C
Guide rail extension
2.3 Adjustment elements
Fig. 2: Adjustment elements
Adjustment elements on the machine
1
Rotary switch
2
Locking pin
3
Rocker switch on and off
4
Plunge bar
5
Wing screw
6
Clamping lever
7
Stop slide
8
Scoring lever
9
Saw blade speed setting wheel
(rear of motor)

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3General 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 machine is only suitable for cutting the following materials:
- Solid wood
- Panel materials
- Wood-fiber insulation material
- Gypsum fiber board
- Cement-bonded panels
- Fiber-cement panels in connection with a diamond saw blade
The maximum stock thickness must not exceed 45 mm.
Use only saw blades that are approved by the manufacturer.
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 with a base body thicker than or a cutting width smaller than the riving knife.
- Saw blades that are not suitable for the no load speed of the saw blade.

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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.
- When using the machine outdoors, the use of an earth leakage circuit breaker is recommended.
- Replace damaged cables or plugs immediately. To avoid safety hazards, only MAFELL or an authorized
MAFELL service workshop is allowed to replace parts.
- Prevent sharp kinks of the cable. Do not wrap the cable around the machine, especially when transporting
and storing the machine.
- 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.
- 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.

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3.4 Specific safety rules
Sawing method
- Do not reach underneath the workpiece. Below the workpiece, the guard cannot protect you from the saw
blade.
- Adjust the cutting depth to the thickness of the workpiece. Less than a full tooth height should be
visible below the workpiece.
- Never hold the workpiece in your hands or across your leg while you are cutting it. Secure the
workpiece on a stable support. It is important to secure the workpiece safely. This minimizes the risk of
body contact, jamming of the saw blade or loss of control over the machine.
- Always use saw blades of the correct size and with a suitable arbor hole (e.g. diamond-shaped or
round). Saw blades that do not match the mounting parts of the saw will run out of true, resulting in a loss of
control.
- Never use damaged or wrong saw blade washers or bolts. The saw blade washers and bolts are
designed specifically for your saw, for optimal performance and operational safety.
- Support large panels to reduce the risk of a kickback from a jammed saw blade. Large panels tend to
sag under their own weight. Panels must be supported on both sides: near the kerf and at the edge.
- Never use blunt or damaged saw blades. The kerf produced by a saw blade with blunt or incorrectly
aligned teeth is too narrow, causing increased friction, jamming of the saw blade and kickback.
Function of the guard
- Before each use, check to ensure that the saw blade can be moved downward out of the protective
hood after the plunge bar has been actuated, and that it returns to its fully retracted position and
engages there when the load is released.The guard can be bent if the saw drops to the ground. Ensure
that the saw blade moves freely and does not get in contact with the guard or other parts at all cutting
angles and cutting depths.
- Check the function of the spring for the guard. Have the saw serviced before use if guard and/or
spring do not function properly. Damaged parts, sticky deposits or accumulations of chips delay the
operation of the guard.
- Never put the saw down on the workbench or the ground when the saw blade is not fully retracted
into the guard. An unprotected coasting saw blade will move the saw in the opposite direction of the cut
and cut whatever is in its path. Be aware of the coasting time of the saw blade.

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Operation information:
- Make sure that no other people are in the saw’s working area while the machine is in operation.
- Using the diagram on the control panel, select the correct saw blade and feed speed based on the material
to be machined.
- Prop the far end of the guide rail if it extends beyond the workpiece to be cut. This will prevent the machine
from tipping over.
- Correctly set the stop slide (which stops the feed movement and automatically returns the saw unit to its
home position) for the workpiece to be processed (workpiece length + 120 mm | 4.72 in).
- Do not remove the machine from the workpiece until the saw blade has come to a standstill and the saw unit
has moved back to its starting position.
- Only use a diamond saw blade when cutting fiber-cement panels.
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 contact surfaces for the antiskid guide rails
Visual check for damage and deformation
Feed and saw blade drive are operated from a single
control point
Visual check for damage and deformation
Riving knife/splitter
Visual check for damage and deformation
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:
- Touching the saw blade that extends below the guide rail when the unit starts to cut.
- Touching the saw blade during and after cutting if the stop slide is not correctly set to automatically return
the unit in its home position.
- The machine might tip over if the far end of the guide rail is not properly supported when it extends beyond
the workpiece to be cut.
- 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.
- Breakage and ejection of the saw blade or parts of the saw blade.
- Impaired hearing when working without hearing protection for long periods of time.
- Emission of harmful wood dusts during longer operation without extraction.
4Setup / adjustment
4.1 Mains connection
Prior to starting up the machine, check to ensure that the mains voltage corresponds to the operating voltage
specified on the rating plate of the machine.
4.2 Routing of the connecting cable
Warning
Electric shock when cutting into the connecting cable
The connecting cable can impair safety functions and work functions and
get into contact with the cutting tool. Cutting into the connecting cable of
the machine puts the metal parts of the machine under tension and causes
an electric shock. There is a risk of injury for the user.
➢When working, pay attention to the way the connecting cable is
routed.
➢Never cut into the connecting cable of your machine.

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4.3 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].
Operation without an extraction system is not
recommended.
Remove the connecting hose 10 between the saw
unit and the chip discharge channel (see illustration) if
you don’t use an external extraction system and work
outdoors or in adequately ventilated rooms.
This avoids clogging the chip discharge channel in
the guide rail when operating without an extraction
system.
Fig. 3: Connection hose between saw unit and chip
discharge channel

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4.4 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 solid wood:
- 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 solid-wood panels, chipboards, cement-bonded chipboards, and multiplex boards:
- Carbide circular saw blade Ø 160 x 1.8 x 20 mm, 24 teeth [Ø 6.30 x 0.07 x 0.79 in]
Cutting solid-wood panels, chipboards, multiplex boards, gypsum fiber boards, HDF, MDF and OSB
boards:
- Carbide circular saw blade Ø 162 x 1.8 x 20 mm, 32 teeth [Ø 6.38 x 0.07 x 0.79 in]
Cutting chipboards, overlaid boards, HPL laminate, HDF, MDF and OSB boards:
- 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 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]
A diagram attached to the control panel shows suitable “material – saw blade –feed speed”
combinations.
Use it for reference when choosing a saw blade.
4.5 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.

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Use the following procedure to change the saw
blade:
1. Pull out the power plug of the machine.
2. Put down the cable where you can see it.
3. Press and hold the locking pin (2).
Fig. 4: Locking the saw shaft
4. Loosen the flange screw 11 by turning it
counterclockwise with the Allen key (B).
➢You can now release the locking pin.
5. Remove the flange screw (11) and the front
clamping flange (12).
6. Use the plunge bar 4 to press down the saw
blade. Tilting the saw blade makes removing it
easier.
7. Remove the old saw blade.
➢Clamping flanges must be free of adhering
parts!
➢The new saw blade can now be installed.
Fig. 5: Removing the old saw blade

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8. Install the new saw blade 13.
➢Ensure that the direction of rotation is
correct when you install the saw blade.
The saw teeth or the arrow on the saw
blade (13) must point in the direction of the
arrow (14) on the machine.
9. Fit clamping flange (12) and flange screw (11).
Fig. 6: Replacing the saw blade
10. Press and hold the locking pin (2).
11. Tighten the flange screw 11 by turning it
clockwise with the Allen key B.
➢You can now release the locking pin 2.
✓The saw blade is changed.
Fig. 7: Securing the saw blade

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4.6 Riving knife
The riving knife prevents the saw blade from jamming during rip cutting. In addition, the riving knife retracts into
the machine during plunge cuts. This prevents kickback during the sawing process.
The correct distance to the saw blade is shown in the figure.
Use the following procedure to adjust the
distance of the riving knife:
1. Pull out the power plug of the machine.
2. Set the unit to its greatest cutting depth.
➢See also chapter 5.6 Cutting depth setting.
3. Adjust the screw 15 by turning it
counterclockwise with the Allen key B.
4. Move the riving knife along its longitudinal slot
to adjust it.
➢Do not exceed the maximum distance to
the saw blade (see Fig.. 8).
5. Then re-tighten screw 15 by turning it
clockwise with the Allen key B.
✓The riving knife distance is set.
Fig. 8: Distance riving knife to saw blade

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5Operation
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. Push the rocker switch 3 forwards and hold it.
➢The saw motor is turned on and the feed
starts 1 second later. The saw motor
accelerates to its operating speed.
✓The machine is switched on
Fig. 9: Switching the machine on
Push the rocker switch 3 backwards to return the saw unit to its starting position. The return
travel is automatically switched off when the home position is reached.
The saw blade may still rotate during return travel.
5.3 Rotational speed setting
Use the following procedure to select the
rotational speed:
1. Select the desired level at the setting wheel (9).
➢At the setting wheel (9), you can adjust the
saw blade speed continuously between
2600 and 5200 rpm.
✓The rotational speed is set.
Fig. 10: Selecting the rotational speed at the setting wheel
The table below shows the saw blade speed settings that are suitable for your application: