Mafell Guide Rails

Operating/Safety Instructions

IMPORTANT Read Before Using

IMPORTANT Lire avant usage

IMPORTANTE Leer antes de usar

These instructions provide essential information for the safe and effective operation of Mafell Guide Rails.

Table of Contents

• 1 Signs and symbols
• 2 Product specifications
  • 2.1 Manufacturer's data
  • 2.2 Technical data
• 3 General safety
  • 3.1 Intended use
  • 3.2 Foreseeable misuse
  • 3.3 Safety instructions
• 4 Working with the guide rail
  • 4.1 Working with the guide rail
  • 4.2 Working with special accessories
• 5 Service and maintenance
  • 5.1 Replacing the anti-splintering device
  • 5.2 Replacing the adhesive section
  • 5.3 Storage
• 6 Optional accessories

1 Signs 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.

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

2 Product specifications

For Guide rail F with item number 204380, 204381, 204365, 204382, 204383
For Guide rail length 3 m [9.84 ft] with item number 200672, 037037, 036553

2.1 Manufacturer's data

MAFELL AG, Beffendorfer Straße 4, D-78727 Oberndorf / Neckar, Phone +49 (0)7423/812-0, Fax +49 (0)7423/812-218, e-mail: mafell@mafell.de

2.2 Technical data

Guide rail F:

Guide rail length 3 m [9.84 ft]:

3 General safety

⚠️ Warning

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

Guide rails F are extruded aluminum profiles with inserted adhesive profiles and a rubber anti-splintering device. The guide rails are only intended for Mafell machines according to the table in Chapter 2.1.

The machine used must have a groove that is placed onto the guide bar of the guide rail. The base plate of the machine slides on the guide rail. This protects the workpiece surface from damage. The red rubber lip of the guide rail serves as a guide edge for cuts as well as an anti-splintering device.

The guide rails can be extended using an F-VS connecting piece (optional equipment), which aligns the parts to be connected in the longitudinal direction. The non-slip support on the workpiece allows precise and clean straight and angled cuts of variable lengths.

Only instructed persons or skilled personnel may use the machine with the guide rail.

3.2 Foreseeable misuse

The guide rails are 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:

• Using a machine that is not intended to be used on with this guide rail.
• 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.

3.3 Safety instructions

READ ALL INSTRUCTIONS!

Non-observance of the instructions listed below can cause electric shock, fire and/or serious injuries.

• Place the machine onto the guide rail in such a way that the guide bar of the guide rail engages with the groove of the machine's base plate. You can lose control of the machine if the machine slips on the guide rail.
• Pull the plug from the socket and/or remove the rechargeable battery before making any adjustments to the machine used with the guide rail. An inadvertent start of the machine can lead to an accident.
• Place the guide rail onto a solid, level, and horizontal surface. The machine used with the guide rail cannot be guided evenly and safely if the guide rail slips or wobbles.
• Even when using the machine with a guide rail, always hold the machine with both hands on the handles provided for this purpose. This is a prerequisite for accurate and safe work.
• When working with guide rails, the machine may only be removed from the workpiece when the tool is at a standstill. An unprotected coasting tool can cause injuries.

RETAIN THESE INSTRUCTIONS!

4 Working with the guide rail

Notice
Risk of damaging the new chip breaker guard due to a blunt saw blade

The installed new chip breaker guard must be cut to size to fit the saw before the first cut.

▶️ Use a sharp saw blade to prevent the chip breaker guard from cracking.

The anti-splintering device can be trimmed with the following machine types: P1 cc, MT55 cc, MT55 18M bl, KSS50 cc, KSS50 18M bl, KSS60 cc, NFU 50

Proceed as follows to set up the anti-splintering device of the guide rail F:

1. Place the guide rail F onto a flat surface (chipboard or similar) along its entire length and fix it with clamp clips.
2. Place the machine you want to work with onto the guide rail.
3. Set the cutting depth of the machine you are using to 3 mm (0.12 in) and the angle scale to 0°.
4. Switch on the machine and advance it steadily in the cutting direction over the entire length of the guide rail.
5. Switch off the machine.

ℹ️ The cut edge of the anti-splintering device corresponds exactly to the left cutting edge of the saw blade.

ℹ️ The edge cut on the anti-splintering device serves as a guide edge for straight and bevel cuts.

✔️ The anti-splintering device is set up.

Important information when setting up the MT55 plunge saw:
Adjust the two setting wheels such that the machine moves in the guide of the rail without any play. Lower the machine to a cutting depth of 3 mm (0.12 in). Switch on the machine to trim the anti-splintering device.

4.1 Working with the guide rail

Guide rail F:

⚠️ Avertissement

Risk of injury when the blade guard is open!

If the machine sits on the guide rail F and is pushed beyond the edge of the material, the pivoting blade guard cannot close by itself because it rests on the guide rail F. Only when the machine is lifted off the guide rail F can the pivoting blade guard close automatically.

▶️ Switch off the machine. Wait until the saw blade has stopped completely. Now you can lift the machine off the guide rail F.

Use the following procedure when working with the guide rail F:

1. Place the guide rail onto the workpiece.
2. Insert a clamp clip at both ends of the guide rail F.
3. Align the guide rail F on the workpiece.
4. Fix the workpiece with the two clamp clips.

[Figure 1: Fix the workpiece with clamp clips.]

5. Place the machine onto the guide rail F such that the guide bar of the guide rail engages with the base plate's groove.
6. Switch on the machine and evenly push it along the guide rail.
7. Switch off the machine and wait until the saw blade has stopped.
8. Lift the machine off the guide rail F.

✔️ Working with the guide rail F is complete.

[Figure 2: Working with the guide rail F.]

Guide rail length 3 m [9.84 ft]:

Use the following procedure when working with the guide rail:

1. Place the guide rail (1) on the workpiece in such a way that the guide bar points upwards and is positioned on the machining side.
2. Align the guide rail on the workpiece and fasten it with nails.
3. Loosen the wing screws (2) on the two adapters.
4. Insert the two adapters into the holes provided on the rip fence (3) of the machine used.
5. Fasten the adapters with the two wing screws (2).
6. Position the machine such that the guide bar (4) of the guide rail engages in the groove of the adapter pair.
7. Set the rip fence to the required cutting distance.

[Figure 3: Placing the guide rail on the workpiece.]

8. Switch on the machine and push it evenly over the guide rail.
9. Make sure that both adapters are always hooked into the guide rail during cutting.
10. Switch off the machine and wait until the saw blade has stopped.
11. Lift the machine off the guide rail.

✔️ Cutting with the guide rail is complete.

[Figure 4: Placing the machine on the guide rail.]

[Figure 5: Cutting a workpiece with a guide rail.]

4.2 Working with special accessories

4.2.1 Using the F-VS connecting piece

The connecting piece F-VS is used to connect two guide rails F or to connect a guide rail F with a special accessory (angular stop F-WA and the Aerofix suction and clamping system F-AF1).

Use the following procedure to work with the F-VS connecting piece:

1. Slide the F-VS connecting piece laterally into the guide rail F, push it up to the center marking and fix it with two eccentric screws.
2. Slide the second guide rail or the optional accessory onto the F-VS connecting piece until the two parts to be connected meet.
3. Fix both parts with the other two eccentric screws.

▶️ The connecting piece aligns the two parts to be connected in the longitudinal direction.

✔️ The F-VS connecting piece is attached.

[Figure 6: F-VS connecting piece for connecting two guide rails.]

Push the F-VS connecting piece completely in, fixed it with eccentric screws, or remove it when not in use.

4.2.2 Using the angular stop F-WA

Use the angular stop F-WA to make bevel cuts from -45° to 60°. Use the F-VS connecting piece to connect the angular stop F-WA with any guide rail F.

Use the following procedure to perform bevel cuts:

1. Use the scale (5) to set the number of degrees for the bevel cut and fix the setting with the locking device (6).
2. Align the angular stop on the workpiece.
3. Cut the workpiece at the set angle.

✔️ The bevel cut is complete.

[Figure 7: Bevel cut settings.]

The guide rail length of the angular stop F-WA is 200 mm [7.87 in] at the 90°position. When setting to 0°, press the pointer into the notch with your thumb, hold it down and fix the locking device.

4.2.3 Using the Aerofix F-AF suction and clamping system

Use the F-VS connecting piece to connect and extend the Aerofix F-AF1 suction and clamping system with the guide rails F. It uses the suction power of the vacuum cleaner and creates a negative pressure under the rail profile.

The suction acts in front of the material from below (e.g. for cross cuts) or on the material (for plunge cuts).

The Aerofix F-AF1 suction and clamping system can be used with these Mafell machines:

• P1 cc
• MT 55 cc
• MT 55 18M bl
• KSS 50 cc
• KSS 60 cc

Use the following procedure for making cross cuts with the Aerofix system:

1. Attach the suction adapter to the bottom of the guide rail so that it is in front of the workpiece.
2. Attach the vacuum cleaner hose to the adapter facing downwards.
3. Insert the machine hose into the rear-facing adapter.

✔️ The Aerofix system is set up for cross cuts.

[Figure 8: Using the Aerofix system for cross cuts.]

Use the following procedure for making plunge cuts with the Aerofix system:

1. Attach the suction adapter to the guide rail.
2. Attach the vacuum cleaner hose to the side facing away from the guide rail.
3. Attach the machine hose to the side facing the guide rail.

✔️ The Aerofix system is set up for plunge cuts.

[Figure 9: Using the Aerofix system for plunge cuts.]

5 Service and maintenance

Remove accumulated dust from the guide rail at regular intervals. Use a vacuum cleaner to clean the guides.

5.1 Replacing the anti-splintering device

Use the following procedure to replace the chip breaker guard:

1. Pull the old anti-splintering device out of the guide rail F.
2. Use the F-SS 3.4 m accessory part as the new anti-splintering device and cut it to the required length.

[Figure 10: Pulling the anti-splintering device out.]

3. Wet the cut anti-splintering device with soapy water.
4. Slide the bulb of the anti-splintering device into the front retainer.

[Figure 11: Inserting the new chip breaker guard.]

5. For instance, using a block of wood, press the second bulb of the anti-splintering device in no particular order into the bottom retainer of the guide rail. This prevents the anti-splintering device from being compressed or stretched.

[Figure 12: Pressing the new anti-splintering device in.]

6. Use the supplied wedge to secure the anti-splintering device against slipping. To do this, press the wedge into the second bulb and then break off the handle.

✔️ The anti-splintering device is replaced.

[Figure 13: Fixing a new anti-splintering device.]

Notice
Risk of damaging the new chip breaker guard due to a blunt saw blade

The installed new chip breaker guard must be cut to size to fit the saw before the first cut.

▶️ Use a sharp saw blade to prevent the chip breaker guard from cracking.

5.2 Replacing the adhesive section

The bottom side of the guide rail F holds red adhesive profiles to prevent the guide rail from slipping on the workpiece to be processed.

Use the following procedure to replace an adhesive section:

1. Pull out the old adhesive section.
2. Use the F-HP 6.8 m accessory as the new adhesive profile and cut it to the required length.

[Figure 14: Pulling the adhesive profile from the bottom side of the guide rail.]

3. Wet the new adhesive profile with soapy water.
4. Use a block of wood to press in the adhesive profile in no particular order so that it is not compressed or stretched.

✔️ The adhesive section is replaced.

[Figure 15: Pressing in the new adhesive profile.]

5.3 Storage

Thoroughly clean the guide rails if you will not use them for quite some time. Spray bare metal parts with a rust inhibitor.

6 Optional accessories

Guide rail F:

• Guide rails F 80 (0.8 m [2.62 ft] long) - Order no. 204380
• Guide rails F 110 (1.1 m [3.61 ft] long) - Order no. 204381
• Guide rails F 160 (1.6 m [5.25 ft] long) - Order no. 204365
• Guide rails F 210 (2.1 m [6.89 ft] long) - Order no. 204382
• Guide rails F 310 (3.1 m [10.17 ft] long) - Order no. 204383
• F-VS connecting piece for connecting two guide rails - Order no. 204363
• Sliding bevel segment F-WA - Order no. 205357
• Guide rail case TZ-FST 1600 for guide rails up to 1.6 m [5.25 ft] in length - Order no. 095257
• Guide rail case set with 2 guide rails F 160, 1 connecting piece F-VS, 2 clamp clips F-SZ180MM, 1 guide rail case - Order no. 209591
• The guide rail case set includes 1 guide rail F 80, 1 guide rail F 160, 1 angular stop F-WA, 1 guide rail case - Order no. 209592
• End caps F-EK - Order no. 205400
• Adhesion profile F-HP 6.8 m - Order no. 204376
• Anti-splintering device F-SS 3.4 m - Order no. 204375
• Clamp clips F-SZ180MM (2 pcs) - Order no. 207770
• Aerofix F-AF suction and clamping system - Order no. 204770

Guide rail length 3 m [9.84 ft]:

• Guide rail length 3 m [9.84 ft] (two-piece with connecting piece) - Order no. 037037
• Guide rail length 3 m [9.84 ft] (one-piece) - Order no. 200672
• Guide rail extension (length 1.5 m [4.92 ft]) - Order no. 036553
• Adapter pair - Order no. 037195

additionally for the machine type ZSX Ec:

• Slider (as height compensation when using guide rails) - Order no. 206047