Mafell Z5Ec Assembly instructions

Z5Ec
170764.0222/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 28
Versión en español
Ver la página 55

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English
Table of contents
1Signs and symbols ........................................................................................................... 3
1.1 Identification of the device................................................................................................5
2Product specifications ......................................................................................................5
2.1 Technical data .................................................................................................................. 5
2.2 Scope of delivery.............................................................................................................. 6
2.3 Adjustment elements........................................................................................................7
3General safety .................................................................................................................. 8
3.1 Intended use..................................................................................................................... 8
3.2 Foreseeable misuse .........................................................................................................8
3.3 Safety instructions ............................................................................................................ 9
3.4 Specific safety rules .......................................................................................................10
3.5 Safety devices ................................................................................................................11
3.6 Residual risks ................................................................................................................. 12
4Setup / adjustment .........................................................................................................12
4.1 Mains connection ...........................................................................................................12
4.2 Routing of the connecting cable ..................................................................................... 12
4.3 Chip extraction ............................................................................................................... 13
4.4 Saw band selection ........................................................................................................ 13
4.5 Changing and adjusting the saw band ...........................................................................14
5Operation........................................................................................................................21
5.1 Startup............................................................................................................................21
5.2 Switching on ...................................................................................................................21
5.3 Rotational speed setting.................................................................................................21
5.4 Switching off ...................................................................................................................22
5.5 Working information ....................................................................................................... 22
5.6 Swiveling the saw band..................................................................................................24
5.7 Conversion to saw used by two persons........................................................................24
6Service and maintenance...............................................................................................25
6.1 Transport and storage.................................................................................................... 26
7Troubleshooting.............................................................................................................. 26
8Optional accessories ...................................................................................................... 27
9Exploded view and spare parts list................................................................................. 27

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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 danger that will cause serious or fatal injuries.
Potentially dangerous situation that can cause serious or
fatal injuries.
Potentially dangerous situation that can cause minor
injuries.
Tab. 4: Structure of warnings

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1.1 Identification of the device
The icons listed and explained below can be found on the rating plate or on the product.
Symbol
Explanation
Symbol
Explanation
V
Volt
1, 2, 3, ...
I, II, III, ...
Rotational speed setting
A
Ampere
rpm
Revolutions per minute
Hz
Hertz
ø
Saw blade diameter
W
Watt
~
Alternating current
kg
Kilogram (weight)
Protection class II
min
Minutes (time)
Read operating instructions
s
Seconds (time)
Protective goggles
n0
Rated speed at no load
Hearing protection
n
Rated speed at normal load
Dust mask
2Product specifications
2.1 Technical data
Universal motor
120 V~, 60 Hz
240 V~, 60 Hz
Current at normal load
15 A
10 A
Rotational speed at no-load operation
650 to 1550 rpm
Cutting speed at no-load operation
6.9 - 16.6 m/s [22.64 - 54-46 ft]
Cutting depth
305 mm [12 in]
Roller diameter
205 mm [8.07 in]
Saw band width
6 –8 mm [0.24 - 0.32 in]
Saw band length
1752 mm [68.98 in]
Saw band thickness max.
0.65 mm [0.03 in]
Band swing
30°
Hose connector diameter
35 mm [1.38 in]
Weight without power cord
13.6 kg [30 lbs]
Dimensions (width x length x height)
450 x 405 x 860 mm [17.72 x 15.94 x 33.86 in]

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2.2 Scope of delivery
Fig. 1: Scope of delivery
Components
A
Hand-held band saw
B
Parallel guide fence
C
Saw bands
Additionally included:
1 handle for use by two persons

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2.3 Adjustment elements
Fig. 2: Adjustment elements
Adjustment elements on the machine
1
Saw band swing lever
2
Knurled screw upper cover
3
Blocking slider
4
Power switch ON
5
Wing screws
6
Power switch OFF
7
Setting wheel for saw band rotational
speed
8
Knurled screw lower cover
9
Band tension star knob
10
Band position star knob

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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 designed exclusively for cutting solid wood and pressure-resistant wood-based panels, using
saw bands with hardened teeth.
The dimension of the saw bands used must be within the following range:
Saw band length
1752 mm [68.98 in] ±10 mm [0.39 in]
Saw band width
6 –8 mm [0.24 - 0.32 in]
Saw band thickness max.
0.65 mm [0.03 in]
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 or warped saw bands.
- Saw bands thicker than 0.65 mm [0.03 in].

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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
Operation information:
- Ensure that the machine is switched off when you connect it to the mains.
- Ensure that you stand in an unobstructed and non-slip area with adequate lighting.
- Prior to switching the machine on, check to ensure that the saw band is properly tensioned and that the
protective covers are in place.
- Always pull out the power plug before you change tools, make adjustments, or eliminate malfunctions (this
also includes removing trapped chips).
- Never work on workpieces that are too small or too large for the machine capacity.
- Always secure the workpiece against slipping away. Use clamps, for example.
- Remove the protective covers of the machine only for changing tools. Never work without protective covers!
- Do not start cutting the workpiece before the saw band has reached its full rotational speed.
- Check the workpiece for foreign bodies. Do not saw into metal parts, such as nails.
- During the sawing process, always ensure that the connecting cable runs away from the machine towards
the rear.
- Adjust the sawing feed rate to the material thickness. Advancing too quickly will overload the motor, results
in improper saw cuts, and causes the saw band to be blunt more quickly.
- During the drilling process, never reach in front of or underneath the workpiece (risk of injury!).
- Never apply lateral counterpressure to the saw band to slow it down.
- Do not remove the machine from the workpiece before the saw band has stopped.
- Never reach into the chip ejector or saw band while the machine is running.
- Use only saw bands with the characteristic data specified in these operating instructions.
- Keep the area under the workpiece free of obstacles. At the same time, pay attention to the machine’s
pivoting range.
- Before starting to saw, pay attention that there are no persons or objects in the surroundings of the saw.
- As the operator, pay attention to the second person during two-man operation. Interrupt the sawing process
if you note any malpractice.
- As the second person, always pay attention to the main operator. Leave the saw intake area if you observe
any malpractice of the main operator. Pull out the mains plug.
- Avoid touching the saw band after a sawing process. The saw band can be hot.
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
Upper and lower cover
Visual check for damage and deformation
Band guard
Visual check for damage
Large base plate
Visual check for damage and deformation
Handles
Visual check for damage
Switching device and mechanical brake
Functional check (braking time must not be longer
than 7 seconds)
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 band in the open section.
- Saw band breaking or jumping off.
- 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].
4.4 Saw band 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 dry and hard wood; for tight curves:
- Saw band 1752 x 6 x 0.65 mm [68.98 x 0.24 x 0.03 in]; 6 teeth per inch
Cutting wet and dry wood; for tight curves:
- Saw band 1752 x 6 x 0.65 mm [68.98 x 0.24 x 0.03 in]; 4 teeth per inch
General purpose for wet and dry wood; curves and straight ripping and cross-cutting:
- Saw band 1752 x 8 x 0.65 mm [68.98 x 0.32 x 0.03 in]; 4 teeth per inch

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4.5 Changing and adjusting the saw band
Caution
Risk of injury from a stopped saw band
The saw band is sharp. You can hurt yourself when you work on the saw band.
➢Wear protective gloves when you work on the saw band.
➢Be careful when you work on the saw band.
Use the following procedure to change the saw
band:
1. Pull out the power plug of the machine.
2. Loosen the knurled screw (2) and remove the
upper cover.
3. Loosen the knurled screw (8) and remove the
lower cover.
Fig. 3: Removing upper and lower cover
4. Loosen the two fillister head screws (11) and
remove the band guard (12).
Fig. 4: Removing the band guard

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5. Turn the star knob (9) counter-clockwise to
release the band tension.
Fig. 5: Releasing the band tension
6. Put down the stopped hand-held band saw in
front of you on the rubber buffer (13) on the
floor and rest it against your legs.
7. Reach from the rear over the hand-held band
saw and pull the lower band saw roll (14) on
the saw band with both hands slightly
upwards. Remove the saw band from the
upper band saw roll (15).
8. Next, lower the saw band.
➢The lower band saw roll (14) is relieved
9. You can now remove the complete saw band.
10. Remove resin residues and chips from the roll
linings.
Fig. 6: Removing the saw band
11. Position the new saw band with the tooth tips
in the sense of rotation first on the lower band
saw roll (14).
➢The sense of rotation is shown by
arrows (16) on the band saw rolls.
12. Using both hands on the saw band, pull up the
lower band saw roll (14) and position the saw
band on the upper band saw roll (15).
Fig. 7: Mounting a new saw band

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13. Manually drive the band saw roll in the sense
of rotation until the saw band is positioned
correctly on the band saw rolls.
Fig. 8: Positioning the saw band
14. Turn the star knob (9) clockwise to tension the
saw band. The correct belt tension is reached
when the slip clutch in the star knob (9)
responds and there is no more visible belt
tensioning.
➢The belt tension is preset at the factory
via a slip clutch. To check, you can
measure the distance "X" between the
base plate and any edge on the lower
swiveling band guide when you change
the saw band. When you turn the star
knob (9), the distance "X" must be
reduced by at least 4 mm [0.16 in] to a
maximum of 6 mm [0.24 in] until the slip
clutch engages.
Fig. 9: Tensioning the saw band

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15. Turn the star knob (10) to adjust the band
position such that the rear of the saw band
rests with a gap of < 1 mm [0.04 in] against
the upper and lower band contact blocks (18)
and the upper and lower slotted bolts (19). In
this process, drive the band saw roll by hand
in the sense of rotation.
➢Turning the star knob (10)
counterclockwise causes a movement
toward the band contact blocks and the
slotted bolts.
➢Turning the star knob (10) clockwise
causes a movement toward the cover.
16. To check, apply pressure to the saw band
from the front in the areas of the band contact
block (18) and the slotted bolt (19) while the
machine is stopped.
➢A minimum movement of the saw band
should be possible (< 1 mm | 0.04 in).
➢The slip clutch must be readjusted if the
saw band cannot be moved or has too
much play. For this, see the information
in chapter 4.5.1 Adjusting the slip clutch.
Fig. 10: Adjusting the band position
17. Secure the band guard (12) with the fillister
head screws (11).
18. Using the knurled screws (2) and (8), screw
the upper and lower covers back on.
✓Saw band change terminated
successfully.
Fig. 11: Mounting band guard and covers

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4.5.1 Adjusting the slip clutch
The slip clutch in the star knob must be adjusted when:
- The distance "X" does not change by at least 4 mm [0.16 in] and no more than 6 mm [0.24 in], or
- the saw band is not in contact with either the upper or the lower band contact block and the slotted bolts
with a gap <1 mm [0.04 in].
Use the following procedure to adjust the slip
clutch:
1. Turn the star knob (9) counter-clockwise to
release the band tension.
2. Note down the distance "X" between the base
plate and any edge on the lower swiveling
band guide.
3. Turn the star knob (9) clockwise to tension the
saw band.
➢The slip clutch in the star knob (9) must
be readjusted if that distance is reduced
by less than 4 mm [0.16 in] or more than
6 mm [0.24 in].
4. Turn the star knob (9) counterclockwise to
release the band tension.
Fig. 12: Noting down the distance
To adjust the slip clutch, the star knob must be relieved.
5. Hold the star knob (9) with one hand and
readjust the slip clutch (17) with an 6-mm
Allen key.
➢Turning counterclockwise reduces the
band tension, turning clockwise
increases the band tension.
6. Tighten the star knob (9).
➢The slip clutch is adjusted correctly when
the distance "X" changes between 4 and
6 mm [0.16 - 0.24 in] when the saw band
is tensioned.
Fig. 13: Adjusting the slip clutch

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7. Turn the star knob (10) to adjust the band
position such that the rear of the saw band
rests with a gap of < 1 mm [0.04 in] against
the upper and lower band contact blocks (18)
and the upper and lower slotted bolts (19). In
this process, drive the band saw roll by hand
in the sense of rotation.
➢Turning the star knob (10)
counterclockwise causes a movement
toward the band contact blocks and the
slotted bolts.
➢Turning the star knob (10) clockwise
causes a movement toward the cover.
8. To check, apply pressure to the saw band
from the front in the areas of the band contact
block (18) and the slotted bolt (19) while the
machine is stopped.
➢A minimum movement of the saw band
should be possible (< 1 mm | 0.04 in).
Fig. 14: Adjusting the band position
9. To check, you can measure the distance "X"
between the base plate and any edge on the
lower swiveling band guide when you change
the saw band.
10. Turn the star knob (9) again to loosen it,
before you tighten it again. The distance "X"
must have changed by at least 4 mm [0.16 in]
and no more than 6 mm [0.24 in].
Fig. 15: Checking the distance "X"

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11. Secure the band guard (12) with the fillister
head screws (11).
12. Using the knurled screws (2) and (8), screw
the upper and lower covers back on.
✓Adjusting the slip clutch completed
successfully.
Fig. 16: Mounting band guard and covers
Belt guard and/or upper and lower cover must always be in place.
The belt guard may only be removed when you are working with the left side of the band.