Mafell ZSX Ec 260 HM Assembly instructions

ZSX Ec
170760.0222/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 35
Versión en español
Ver la página 68

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English
Table of contents
1Signs and symbols ........................................................................................................... 3
1.1 Identification of the device................................................................................................5
2Product specifications ......................................................................................................6
2.1 Technical data .................................................................................................................. 6
2.2 Scope of delivery.............................................................................................................. 7
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 Changing the saw chain ................................................................................................. 13
4.4 Chain tension ................................................................................................................. 17
4.5 Chain lubrication............................................................................................................. 19
4.6 Adjusting the parallel guide fence .................................................................................. 22
4.7 Adjustment for angle cuts...............................................................................................23
5Operation........................................................................................................................25
5.1 Startup............................................................................................................................25
5.2 Switching on ...................................................................................................................25
5.3 Rotational speed setting.................................................................................................25
5.4 Switching off ...................................................................................................................26
5.5 Working information .......................................................................................................26
5.6 Working with special accessories................................................................................... 28
6Service and maintenance...............................................................................................29
6.1 Machine maintenance .................................................................................................... 29
6.2 Maintenance of the chain fitting......................................................................................30
6.3 Sprocket wheel............................................................................................................... 30
6.4 General sharpening information ..................................................................................... 31
6.5 Transport and storage.................................................................................................... 31
7Troubleshooting.............................................................................................................. 32
8Optional accessories ...................................................................................................... 33
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
Tool (saw chain type)
260 HM
400 HM
400 Q
Number of driving elements
32
40
78
Chain pitch
18 mm [0.71 in]
18 mm [0.71 in]
3/8"
Cutting width
6.8 mm [0.27 in]
6.8 mm [0.27 in]
6.8 mm [0.27 in]
Cutting speed at normal load
13.5 - 16.4 m/s
[44.29 - 53.81 ft./s]
13.5 - 16.4 m/s
[44.29 - 53.81 ft./s]
14.0 - 17.0 m/s
[45.93 - 55.77 ft./s]
Swivel range on both sides
60°
60°
60°
Cutting depth
at 0°
260 mm [10.24 in]
400 mm [15.75 in]
400 mm [15.75 in]
at 15°
251 mm [9.88 in]
386 mm [15.20 in]
386 mm [15.20 in]
at 30°
225 mm [8.86 in]
346 mm [13.62 in]
346 mm [13.62 in]
at 45°
184 mm [7.24 in]
282 mm [11.10 in]
282 mm [11.10 in]
at 60°
130 mm [5.12 in]
199 mm [7.83 in]
199 mm [7.83 in]
Chain fittings swiveling to the rear
through 10°°
Machine dimensions
Width x length
450 x 632 mm
[17.72 x 24.88 in]
450 x 632 mm
[17.72 x 24.88 in]
450 x 632 mm
[17.72 x 24.88 in]
High (incl. tool-related guide fence)
662 mm [26.06 in]
800 mm [31.50 in]
800 mm [31.50 in]
Base plate
300 x 506 mm
[11.81 x 19.92 in]
300 x 506 mm
[11.81 x 19.92 in]
300 x 506 mm
[11.81 x 19.92 in]
Width without guide fence
300 mm [11.81 in]
300 mm [11.81 in]
300 mm [11.81 in]
Height without tool and riving
knife/splitter
312 mm [12.28 in]
312 mm [12.28 in]
312 mm [12.28 in]
Weight without power cord
13.3 kg [29.32 lbs]
14.1 kg [31.08 lbs]
11 kg [24.25 lbs]
Motor data
All variants
General-purpose motor interference suppressed for radio and TV
120 V~, 60 Hz
Current at normal load
20 A
No-load speed
18000 to 21500 rpm
Rotational speed of the chain pinion
No load
Normal load
3000 to 3600 rpm
2800 to 3400 rpm

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2.2 Scope of delivery
Fig. 1: Scope of delivery
Components
A
Carpentry chainsaw
B
Guide bar
C
2 saw chains
D
Parallel guide fence
E
Combination wrench in bracket on the
machine
2.3 Adjustment elements
Fig. 2: Adjustment elements
Adjustment elements on the machine
1
Locking lever
2
Setting wheel
3
Oil tank cover
4
Chip ejector
5
Wing screws
6
Swivel setting handle
7
Operating lever
8
Swivel setting scale
9
Swivel setting locking screw

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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 exclusively suitable for longitudinal and cross cutting of solid wood up to a maximum thickness
of 400 mm [15.75 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.
- Using the machine with third-party tools. Only the special saw chains suggested by MAFELL are allowed.

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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
- Ensure that you stand in an unobstructed and non-slip area with adequate lighting.
- 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.
- Whenever possible, secure the workpiece, for example with screw clamps, against swinging away, slipping,
tipping over or bobbing up.
- Use only genuine MAFELL saw chains. Commercially available saw chains are not suitable for this machine.
After each chain change, check to ensure that the chain tension is correct.
- Never remove the riving knife/splitter, including the guard sheet for the lower chain deflection.
- The machine may only be operated by one single person.
- During work, the base plate of the machine must rest on the workpiece.
- Prior to starting work, ensure that there is enough oil for the chain lubrication in the tank and that chain
lubrication is working.
- Hold the machine tight and support it before you switch it on. This requires rail and chain to be unobstructed.
Do not start cutting the workpiece before the saw chain has reached its full rotational speed. Ensure that you
stand securely.
- Never clamp the switch.
- Never reach under the base plate or into the chip ejector while you are sawing.
- Never transport the machine when the saw chain is running.
- Ensure that the running chain only comes into contact with the workpiece, never with other objects.
- Remove the cover on the chain sprocket only to change the tool. Replace it immediately afterward. Never
remove it while the machine is running.
- The machine cannot be connected to an exhaust system. Consequently, it may only be used outdoors or in
adequately ventilated rooms.
- Never change the initial cutting direction forcibly. Guide the saw such that the pressure does not cause the
chain to stop.
- Check the workpiece for foreign bodies. Never saw into metal parts, such as nails.
- While you are sawing, ensure that the connecting cable always runs towards the rear, away from the
machine.
- Pull out the power plug immediately if a connecting cable is damaged or cut.
- 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 chain to be blunt more quickly.
- Do not remove the machine from the workpiece before the saw chain has stopped. This happens very
quickly due to the integrated brake.
- Do not operate the machine with bent or damaged riving knife.
- Ensure that the handles are free from chain oil.
- Keep the area under the workpiece free of obstacles. At the same time, pay attention to the machine’s large
pivoting range.

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- Note that the saw chain and the guide rails can be hot shortly after processing.
- Note that cuttings falling down when sawing large workpieces can cause injuries.
- Be particularly careful when sawing the last workpiece to be sawed. The machine’s supporting surface will
be reduced. If necessary, clamp an additional workpiece to ensure the machine has a stable support.
RETAIN THESE INSTRUCTIONS!
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
Large base plate and parallel guide fence
Visual check for damage and deformation
Bottom deflection with guard sheet
Visual check for damage
Riving knife/splitter
Visual check for damage and deformation
Handles
Visual check for damage
Switching device and brake
Functional check (braking time must not be longer
than 7 seconds)
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:
- Ejected wood cuttings
- Touching the running saw chain below the base plate.
- Touching the stopped saw chain below the base plate.
- Kickback of the machine when jammed in the workpiece.
- Breaking of the saw chain.
- 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 Changing the saw chain
Caution
Risk of injury from a stopped saw chain
The saw chain is sharp. You can hurt yourself when you change the saw chain.
➢Be careful when you change the saw chain.
➢Wear protective gloves when you change the saw chain.
Use the following procedure to change the saw
chain:
1. Pull out the power plug of the machine.
2. Put down the cable where you can see it.
3. Open the spring-loaded lower protective flap
(11) downward.
4. Using the combination screwdriver (B), turn
the fillister head screw (10) counterclockwise
to loosen it.
Fig. 3: Opening the protective flap
5. Open the cover and remove it.
Fig. 4: Removing the cover

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6. Using the combination screwdriver (B), turn
the hexagon socket screw (12)
counterclockwise to loosen it.
7. Remove the intermediate cover (13) and the
oil tank (14).
Fig. 5: Removing intermediate cover and oil tank
8. Using the combination screwdriver (B), loosen
the fastening bolt (15) at the bottom of the
guide bar counterclockwise to loosen it.
9. Open the guard sheet (16).
Fig. 6: Opening the guard sheet at the guide bar
10. Using the combination screwdriver (B), turn
the clamping screw (17) counterclockwise to
loosen it.
➢Chain tension released.
11. Remove the guide bar together with the saw
chain.
12. Remove the old saw chain.
Fig. 7: Release the chain tension and remove the guide
bar together with the saw chain

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13. Mount a new / freshly sharpened saw chain on
the guide bar.
14. Insert the guide bar together with the saw
chain into the machine guide.
➢The chain tensioning bolt (18) must
engage in the bore provided for it in the
guide bar.
➢The cutting edges of the chain teeth
must point in the direction of the marking
(19) for the running direction.
15. Using the combination screwdriver (B), rotate
the gearbox shaft (20) such that the mounted
saw chain smoothly engages into the driver
toothing of the gearbox shaft.
Fig. 8: Mounting a guide bar with new / freshly sharpened
saw chain
16. Mount the intermediate cover (13).
17. Using the combination screwdriver (B), turn
the hexagon socket screw (12) clockwise to
slightly lock it.
18. Insert the oil tank (14).
Fig. 9: Inserting intermediate cover and oil tank
19. Turn the tensioning screw (17) clockwise until
the correct chain tension is reached.
➢For this, see the information in chapter
4.4 Chain tension.
20. Using the combination screwdriver (B), turn
the hexagon socket screw (12) clockwise to
tighten it.
Fig. 10: Tightening the chain tension

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21. Close the guard sheet (16) at the bottom of
the guide bar.
22. Using the combination screwdriver (B), turn
the hexagon socket screw (15) clockwise to
tighten it.
Fig. 11: Closing the guard sheet at the guide bar
23. Insert the cover and close it.
Fig. 12: Inserting the cover
24. Insert the fillister head screw (10). Using the
combination screwdriver (B), turn it clockwise
to tighten it.
25. Close the spring-loaded lower protection flap
(11) upward.
✓The saw chain is changed.
Fig. 13: Closing the protective flap
A new saw chain must be run in at idle speed for approx. 2 to 3 minutes after it has been
mounted. Ensure that there is sufficient chain lubrication during this process. After this
initial run-in, it may be necessary to correct the chain tension.

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4.4 Chain tension
Safe operation of the machine and a long service life of the entire chain fitting require a correct chain tension.
This tension must therefore be checked before starting work and every now and then during the operation. The
chain tension is correct when the cold saw chain is in contact with the guide rail and can be lifted off by hand
by 3 to 4 mm [0.12 - 0.16 in].
The saw chain elongates and sags when it is at operating temperature. The saw chain must be tensioned if the
elongation is such that the connecting links on the bar come out of the guidance.
Notice
Risk of damaging the machine when the saw chain shrinks. When cooling down to ambient temperature,
especially at a very low outside temperature, the contraction of the saw chain can exert very high shrinkage
stresses on the machine.
➢If the saw chain requires tensioning once it is at operating temperature, releasing the tension from the
saw chain after finishing the sawing work is absolutely necessary.
Use the following procedure to retension the
saw chain:
1. Pull out the power plug of the machine.
2. Put down the cable where you can see it.
3. Open the spring-loaded lower protective flap
(11) downward.
Fig. 14: Opening the protective flap
4. Using the combination screwdriver (B), turn
the fastening screw (15) at the bottom of the
guide bar counterclockwise to loosen it
slightly.
5. Open the guard sheet (16).
Fig. 15: Opening the guard sheet at the guide bar

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6. Insert the combination screwdriver (B) through
the bottom opening in the cover and turn the
hexagon socket screw (12) counterclockwise
to loosen it slightly.
7. Using the combination screwdriver (B), adjust
the tensioning screw (17) through the upper
opening in the cover.
➢Rotating clockwise means increasing
the chain tension. Rotating
counterclockwise means reducing the
chain tension.
8. Using the combination screwdriver (B), turn
the hexagon socket screw (12) clockwise to
tighten it.
Fig. 16: Adjusting the chain tension
9. Close the guard sheet (16) at the bottom of
the guide bar.
10. Using the combination screwdriver (B), turn
the hexagon socket screw (15) clockwise to
tighten it.
Fig. 17: Closing the guard sheet at the guide bar
11. Close the spring-loaded lower protection flap
(11) upward.
✓The saw chain is retensioned.
Fig. 18: Closing the protective flap

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A new saw chain must be retensioned repeatedly until it has reached its final length. This
is required more frequently than with a chain that has already been used for some time.
4.5 Chain lubrication
Notice
A dry running chain can cause irreparable damage to the entire chain fitting within a short time.
➢Before each start of work, check the oil level in the lubricating oil tank and the proper functioning of the
chain lubrication system.
The correct lubrication of the saw chain is crucial for its service life. Lubrication is sufficient when you can see a
trace of oil between the saw chain and the guide rail.
The oil level in the lubricating oil tank must not be
below the mark (21) next to the inspection window.
Oil can be filled in at the oil tank cap (3). The filling
capacity of the oil tank is approx. 0.3 liters
[0.08 US gal.].
Fig. 19: Oil level in the lubricating oil tank
Only use biodegradable oil for refilling.
Use commercially available oil binders to take up any spilled oil.
Also observe the information provided by the oil manufacturer when you handle oil.
The delivery quantity of the integrated oil pump can be adjusted. Normal dosing was set at the factory. This
shows by a trace of oil that is visible between the saw chain and the guide rail. You may change this dosage if
necessary.

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Use the following procedure to change the
dosing of the oil pump:
1. Pull out the power plug of the machine.
2. Put down the cable where you can see it.
3. Open the spring-loaded lower protective flap
(11) downward.
4. Using the combination screwdriver (B), turn
the fillister head screw (10) counterclockwise
to loosen it.
Fig. 20: Opening the protective flap
5. Open the cover and remove it.
Fig. 21: Removing the cover
6. Using the combination screwdriver (B), turn
the hexagon socket screw (12)
counterclockwise to loosen it.
7. Remove the intermediate cover (13) and the
oil tank (14).
Fig. 22: Removing intermediate cover and oil tank