XL DF 700 - Milling machine FESTOOL - Free user manual and instructions

USER MANUAL XL DF 700 FESTOOL

Original operating manual The illustrations specified are located at the begin- ning and end of the operating manual. 1Symbols 2Technical data 3 Machine features 4 Intended use The machine is intended to create DOMINO dowel connections in hard and soft wood, chipboard, ply- wood and fibreboard. All applications beyond this are regarded as unintended use. The machine is designed and approved for use by trained persons or specialists only. The user is liable for improper or non-in- tended use. 5 Safety instructions

5.1 General safety instructions

21000 rpm Routing depth 15 - 70 mm Routing width, max. 16,5 mm + Ø cutter Ø cutter, max. 14 mm Connecting thread of the drive shaft M8 x 1 Weight (excluding cable) 5,2 kg Safety class /II [1-1] Rubber buffer [1-2] Stop pins [1-3] Handles [1-4] On/Off switch [1-5] Display for dowel hole width [1-6] Adjusting lever for dowel hole width [1-7] Slide for routing depth adjustment [1-8] Snap button for routing depth adjustment [1-9] Marker for routing depth adjustment [1-10] Unlocking of motor unit/guide frame [1-11] Selection slide for routing height adjust- ment [1-12] Clamp lever for routing angle adjustment [1-13] Button for releasing stop pins [1-14] Clamp lever for routing height adjustment [1-15] Extractor connector [1-16] Spindle lock [1-17] Mains power cable Joiner DF 700 EQDF 700 EQ

5.2 Machine-related safety instructions

Hold power tool by insulated gripping surfaces, because the cutter may contact its own cord. Cutting a "live" wire may make exposed metal parts of the power tool "live" and could give the operator an electric shock.

The tools must be rated for at least the speed marked on the power tool. Tools running over rated speed can fly apart and cause injury.

Use the machine only with the guide frame mounted. The guide frame protects the user against broken-off parts of the jointer bit and ac- cidental contact with the jointer bit.

Only cutters provided by Festool for this pur- pose may be mounted on the power tool. The use of other cutters is prohibited due to the in- creased risk of injury.

Never use dull or damaged mortising bits. Dull or damaged mortising bits can cause the tool to lurch sideways unexpectedly and lead to a loss of control of the power tool.

Do not resharpen cutters more than twice. Re- sharpened cutters may affect the precision of the cutting results.

Do not operate the tool if the spring-loaded fence does not return to its forward rest posi- tion. The fence covers the mortising bit and pre- vents accidental contact. If the slides of the fence do not move freely, have the tool serviced imme- diately.

Levels determined in accordance with EN 60745 are typically: Vibration emission value a

(vector sum for three directions) and uncertainty K measured in accor- dance with EN 60745: The specified emissions values (vibration, noise) – are used to compare machines. – They are also used for making preliminary esti- mates regarding vibration and noise loads during operation. – They represent the primary applications of the power tool. Increase possible for other applications, with other insertion tools or if not maintained adequately. Take note of idling and downtimes of machine! 6Operation Always switch the machine off before con- necting or disconnecting the mains power cable! Connecting and detaching the mains power cable [1-17] see Fig. [2]

The switch [1-4] is an on/off switch (I = ON, 0 = OFF).

Peel off the protective film from the bottom of the guide frame [3-4]

Remove the transport safety device [1-18]

The machine features full-wave phase control elec- tronics with the following features: Smooth start-up The electronically controlled smooth start-up en- sures that the machine starts up jolt-free. Constant speed The motor speed remains constant through electron- ic control to ensure a uniform cutting speed even Sound pressure level L

= 94 dB(A) Measuring uncertainty allow- ance K = 3 dB CAUTION Operating noise Damage to hearing

WARNING Unauthorised voltage or frequency! Risk of accident

The mains voltage and the frequency of the pow- er source must correspond with the specifica- tions on the machine's name plate.

In North America, only Festool machines with the voltage specifications 120 V/60 Hz may be used. WARNING Risk of injury, electric shock

Always pull the mains plug out of the socket be- fore performing any type of maintenance on the machine!14 DF 700 EQ

when under load. Temperature cut-out The machine power supply is limited and the speed reduced if the motor exceeds a certain tempera- ture. The machine continues operating at reduced power to allow the ventilator to cool the motor quickly. If the machine temperature exceeds the maximum permitted value for longer periods, the machine switches off completely after approx. 40 seconds and can only be switched on again once the motor has cooled sufficiently. Restart protection The integral restart protection prevents the ma- chine from automatically starting up again after an interruption in power when the machine is used in continuous operating mode. In this case the ma- chine must be switched off and then switched back on again.

Lift the unlocking device [3-2] until it audibly disengages using the open-ended spanner [3-

Press and hold the spindle lock [4-1]

Loosen the cutter [4-3] using the open-ended spanner [4-2] and remove.

Release the spindle lock [4-1]

Press and hold the spindle lock [4-1]

Use the open-ended spanner [4-2] to screw on the cutter [4-3]

Release the spindle lock [4-1]

Slide the guide frame [3-4] onto the motor unit [3-5] until it audibly engages.

Press one or two snap buttons [1-8]

Set the slide for the routing depth setting [1-

to the desired routing depth (15 - 70 mm).

Check whether the slide [1-7] has engaged cor- rectly.

With the two markers [1-9] , you can mark two routing depths and switch easily between them using the slide [1-7] (e.g. for asymmetric DOMI- NO dowel depth distribution).

7.4 Setting the Fence Height

The alignment of the clamp levers [1-12] and [1-14] can be aligned by raising the levers. When tightened, the levers should not protrude beyond the contact surface. a) with selection slide

Loosen the clamp lever for the routing height adjustment [5-1]

Using the front handle [5-2] raise the front part of the guide frame.

Use the selection switch to set [5-6] the desired routing height

Press the front section of the guide frame down- wards as far as the stop.

Close the clamp lever [5-1]

Loosen the clamp lever for the routing height adjustment [5-1]

Pull the selection slide [5-6] as far as the stop in the direction of the motor unit. CAUTION Hot and sharp tools Risk of injury

Do not use insert tools that are blunt or defec- tive.

Wear protective gloves. WARNING Risk of injury

Before inserting a new cutter ensure that the machine, the guide frame and the guides [3-1] and [3-6] are clean.

Remove any contamination that may be present.

Only use sharp, undamaged and clean tools. WARNING Cutter can come out at the rear side of the work- piece. Risk of injury

Set the routing depth at least 5 mm less than the workpiece thickness.DF 700 EQ

Set the desired routing height

using the scale [5-3] by moving the front section of the guide frame vertically.

Close the clamp lever [5-1]

7.5 Setting the Fence Angle

using the scale [5-5] variable from 0° to 90°.

Set the routing height and depth as low as possible when mitre routing as otherwise there is a risk that the cutter will come out the other side.

7.6 Setting the Mortise Width

Use the adjusting lever [1-6] to adjust the width of the dowel hole you intend to cut for an adequate fit or set with 3 mm play: You can see on the display [1-5] what dowel hole width is selected.

7.7 Setting stop pins

Six stop pins [1-2] are available on the stop side of the DOMINO joining machine. Stop pins that are not required can be individually engaged by exerting overpressure and released us- ing the button [1-13]

These serve as spacers to the cutter centre and can be inserted at different locations - see image [6]

At the extractor connector [1-15] , a Festool mobile dust extractor with an extraction hose diameter of 27 mm can be connected.

7.9 Widening the contact surface

The contact surface widening device [7-1] can be used to enlarge the contact surface when routing on the workpiece edge, thus allowing safer guid- ance of the machine.

Secure the contact surface widening device us- ing the two screws [7-2] on the threaded holes [7-3] of the guide frame. The contact surfaces of the contact surface wid- ening device [7-5] and the table [7-4] must be level. 8 Working with the machine Wood is a natural, non-homogenous material and because of this, its dimensions will most likely de- viate slightly during processing, even if the machine is set accurately. Machine handling also influence the degree of working accuracy (e.g. fast-feed speed). Furthermore, the dimensions of wooden DOMINOs may vary (for example, due to humidity), regardless of how they are stored. All of these fac- tors influence the dimensional accuracy of manu- factured dowel holes and dowelling joints.

We recommend routing and joining a test work- piece before machining the actual workpiece. Please observe all mentioned safety infor- mations and the following rules when work- ing: – Always secure the workpiece in such a manner that it cannot move while being processed. – Always hold the machine with two hands on the handles [1-3] when performing work. This re- duces the risk of injury and is a prerequisite for precise work. – Close the clamp lever for routing height adjust- ment [1-14] and the clamp lever for angle adjust- ment [1-12] to avoid unintentional loosening during operation. – Adapt the feed rate to the cutter diameter and material. Work with a constant feed rate – Only lay the machine aside when the cutter has come to a complete standstill. – Always connect the machine to a dust extractor. For work that generates dust, wear a dust mask. Procedure Proceed as follows to create a DOMINO dowelling joint: Tight fitting dowel 13.5 mm + cutter diameter Dowel with lateral play

16.5 mm + cutter diameter

A Three possible spacings to a supply side (1 -

B Two dowel holes beside each other from a supply side (1 - 3) C Two dowel holes by changing the workpiece, e.g. for cross-section cut. WARNING Dust hazard

Dust can be hazardous to health. Always work with a dust extractor.

Always read applicable national regulations be- fore extracting hazardous dust.16 DF 700 EQ

9 Service and maintenance The machine is equipped with special carbon brushes. If they are worn out, the power is inter- rupted automatically and the machine comes to a standstill. Observe the following instructions:

To ensure constant air circulation, always keep the cooling air openings in the housing clean and free of blockages.

Clean the guides [3-1] and [3-6] of dust depos- its.

Oil the guides regularly and lightly with resin- free oil (e.g. sewing machine oil).

We recommend an annual inspection and/or a check after approx. 100 operating hours at an authorised customer service workshop. This is for the safety of the user and the value stability of the power tool. 10 Troubleshooting See chapter

1. Select a DOMINO dowel and insert the

suitable bit into the DOMINO joining machine.

2. Set the routing depth. 7.3

3. Set the routing height. 7.4

4. Adjust the routing angle if necessary. 7.5

5. Mark the areas on the workpieces that

belong together [8-1] so that you will be able to join them correctly again once you have cut the dowel holes.

6. APosition the two workpieces to be joined

against one another and mark the desired positions of the DOMINO dowels with a pencil [8-2]

Select the required stop pins. 7.7

7. Set the desired dowel hole width (ade-

quate fit or with 3 mm play).

8. Cutting the dowel holes

– The first dowel hole by attaching the stop pin to the side edge of the work- piece. – The following dowel holes according to the previously made pencil mark- ings and the scale of the vision panel [8-3]

Our recommendation: Please check each dowel hole for chippings and clear these if necessary. Always work with a dust extractor to improve the removal of chippings. Route the first hole for each workpiece without play (dowel hole width = DOM- INO dowel width) and the other dowel holes with the large dowel hole width. WARNING Risk of injury, electric shock

Always disconnect the mains plug from the socket before performing maintenance work on the machine!

All maintenance and repair work which requires the motor housing to be opened must only be carried out by an authorised service workshop. See chapter Fault Cause Solution Burns Blunt cutter Use sharp cutter Dowel hole too narrow. DOMINO dowel cannot be jointed. a. Blunt cutter b. Deposits (e.g. chippings in the dowel hole) a. Use sharp cutter b. Remove deposit and work with dust extractor Widening of the dowel hole with 8mm cutter Routing depth too large (larger than 50 mm) Reduce routing depth (max.50 mm) Splinters at edge of dowel hole Excessive feed rate Reduce feed rate Dowel hole not parallel to work- piece edge Workpiece has shifted during processing Secure workpiece properlyDF 700 EQ

11 Accessories The order numbers of the accessories and tools can be found in the Festool catalogue or on the Internet under "www.festool.com". Festool provides comprehensive accessories which allow you to use your machine effectively and for di- verse applications, e.g.:

• Handrail fence RA-DF 500/700

• Cross stop QA-DF 500/700

• Stopper LA-DF 500/700 Assembly instructions are included at the end of the operating manual. 12 Environment Do not dispose of electric power tools in house- hold waste! Recycle devices, accessories and packaging. Observe applicable country-specific regulations. EU only: In accordance with European Directive on waste electrical and electronic equipment and im- plementation in national law, used electric power tools must be collected separately and handed in for environmentally friendly recycling. Information on REACh: www.festool.com/reach

ol cannot be loosened during tool change Spindle lock not functioning Twist spindle against the tool using an open-ended spanner. If this occurs several times contact the after-sales service department. The positions of the dowel holes which are created with one of the left and one of the right stop pins do not match precisely. The stop pins are selected differ- ent on the right and left. Select the same stop pins on the left and the right. DOMINO joining machine oper- ates irregularly, jerks a. No dust extractor connected b. Rubber buffer [1-1] worn a. Connect dust extractor b. Replace rubber buffer (spare part) Fault Cause Solution18 DF 700 EQ

(10 mm; 15 mm; 20 mm; 25 mm; 30 mm; 40 mm) in.

Mantenha as guias [3-1]

EU Declaration of Conformity. We declare under sole responsibility that this product complies with all the relevant requirments in the following EU Direc- tives, and following standards and normative docu- ments were applied: