1. Introduction
This manual provides essential information for the safe and efficient operation, maintenance, and troubleshooting of your Mafell MT55 cc MaxiMAX 160mm Plunge Saw. Please read this manual thoroughly before using the tool and keep it for future reference.
The Mafell MT55 cc is a versatile plunge saw designed for high-precision cutting tasks. It excels in plunge cuts, cross-cuts, bevel cuts, and angular cuts on various materials, including solid wood, cement fiber boards, Trespa, OSB, gypsum fiber boards, plastics, facade panels, and other panel materials.
2. Safety Instructions
Always observe general power tool safety guidelines to prevent electric shock, fire, and serious injury. Keep this manual accessible for quick reference.
- Work Area Safety: Keep the work area clean and well-lit. Cluttered or dark areas invite accidents. Do not operate power tools in explosive atmospheres, such as in the presence of flammable liquids, gases, or dust.
- Electrical Safety: Power tool plugs must match the outlet. Never modify the plug in any way. Avoid body contact with earthed or grounded surfaces. Do not expose power tools to rain or wet conditions.
- Personal Safety: Always wear eye protection. Use hearing protection when operating noisy tools. Dress properly; avoid loose clothing or jewelry. Secure long hair.
- Tool Use and Care: Do not force the power tool. Use the correct power tool for your application. Disconnect the plug from the power source before making any adjustments, changing accessories, or storing power tools.
- Specific Plunge Saw Safety: Ensure the blade is sharp and clean. Always use the appropriate blade for the material being cut. Secure the workpiece firmly. Maintain a firm grip on the tool.
3. Package Contents
Upon unpacking, verify that all components listed below are present and undamaged:
- 1 x Mafell MT55 cc Plunge Saw
- 1 x HM Saw Blade 162 x 1.2/1.8 x 20 mm, Z 48, WZ (Part No. 092584)
- 1 x Parallel Guide (Part No. 201436)
- 1 x MT-PA Position Indicator (Part No. 205398)
- 1 x Connection Cable with Plug, 4m (Part No. 087323)
- 1 x Mafell MAX Systainer Case
4. Components and Parts Identification
Key components include the motor housing, plunge mechanism, depth adjustment scale, angle adjustment lever, saw blade guard, dust extraction port, and main handle.
5. Setup
5.1. Blade Installation
- Ensure the tool is unplugged from the power source.
- Open the saw blade cover. (Refer to Figure 4.3)
- Press the spindle lock button to secure the arbor.
- Use the provided wrench to loosen the arbor nut.
- Remove the old blade (if applicable) and clean the arbor flanges.
- Place the new blade onto the arbor, ensuring the rotation direction matches the arrow on the saw.
- Tighten the arbor nut securely with the wrench while holding the spindle lock.
- Close the saw blade cover.
5.2. Connecting to Power
Connect the 4m power cable to a suitable 230V/50Hz power outlet. Ensure the power supply matches the tool's requirements.
6. Operating Instructions
6.1. Adjusting Cutting Depth
The cutting depth can be adjusted precisely to the millimeter. The MT55 cc features a unique depth adjustment mechanism that displays the exact cutting depth, whether used with or without a guide rail. (Refer to Figure 4.5)
- Loosen the depth adjustment knob.
- Move the plunge mechanism to set the desired cutting depth using the scale.
- Tighten the depth adjustment knob firmly to secure the setting.
6.2. Adjusting Bevel Angle
The saw allows for bevel cuts from -1° to +48°. The angle adjustment is secured at two points with a single clamping screw for stability.
- Loosen the angle adjustment clamping screw.
- Tilt the saw base to the desired angle.
- Tighten the clamping screw to lock the angle.
6.3. Pre-Scoring Function
The pre-scoring function can be activated with a simple turn, allowing the MT55 cc to produce clean, splinter-free edges comparable to a stationary machine, even with a worn splinter guard.
To activate pre-scoring, engage the dedicated pre-scoring lever or knob (location may vary, refer to tool markings) before making the main cut.
6.4. Using with Guide Rail
For optimal precision and straight cuts, use the MT55 cc with a Mafell guide rail. The saw's base is designed to fit securely onto the rail. (Refer to Figure 4.2 and 4.4)
The Aerofix F-AF 1 suction clamping system (sold separately) can be used with the MT55 cc for perfect cuts and easy handling.
7. Maintenance
7.1. Cleaning
Regular cleaning is crucial for maintaining the tool's performance and longevity. The closed saw blade housing and protective slider ensure very low dust production, but regular cleaning is still recommended.
- Always unplug the tool before cleaning.
- Use a brush or compressed air to remove dust and debris from ventilation openings and moving parts.
- Wipe down the exterior with a damp cloth. Do not use harsh chemicals or solvents.
- Clean the guide rail grooves and the saw's base plate to ensure smooth operation.
7.2. Blade Care
A sharp blade is essential for safe and efficient cutting. Replace dull or damaged blades promptly.
- Inspect the blade for wear, cracks, or missing teeth before each use.
- Clean resin and pitch buildup from the blade using a suitable blade cleaner.
- Store blades properly to prevent damage.
8. Troubleshooting
| Problem | Possible Cause | Solution |
|---|---|---|
| Saw does not start | No power supply; Faulty switch; Damaged cable | Check power connection; Test outlet; Inspect cable for damage; Contact service if switch is faulty. |
| Excessive vibration or poor cut quality | Dull or damaged blade; Incorrect blade installation; Loose components | Replace blade; Ensure blade is installed correctly and arbor nut is tight; Check for loose screws. |
| Saw bogs down during cutting | Overfeeding; Dull blade; Incorrect speed setting for material | Reduce feed rate; Replace blade; Adjust speed control (if applicable) for harder materials. |
| Dust extraction ineffective | Dust port clogged; Dust bag/vacuum full; Improper connection | Clear dust port; Empty dust bag/vacuum; Ensure secure connection to dust extraction system. |
For issues not listed here, or if solutions do not resolve the problem, please contact Mafell authorized service centers.
9. Specifications
| Feature | Specification |
|---|---|
| Model | MT55 cc MaxiMAX (917603) |
| Rated Power Input | 1400 W |
| Voltage | 230 V / 50 Hz |
| No-load Speed | 6250 rpm |
| Saw Blade Diameter | 160 mm (162 mm included) |
| Max. Cutting Depth (without rail) | 57 mm |
| Bevel Angle Range | -1° to +48° |
| Weight | 4.7 kg |
| Blade Material | Carbide (for included blade) |
| Power Source | Corded Electric |
10. Warranty and Support
Mafell products are manufactured to high quality standards and undergo strict quality controls. For information regarding warranty terms and conditions, please refer to the warranty card included with your product or visit the official Mafell website.
For technical support, spare parts, or service inquiries, please contact your authorized Mafell dealer or service center. Always provide the model number (MT55 cc MaxiMAX) and serial number of your tool when seeking support.
Official Website: www.mafell.com
