KF 1000 - Milling machine Mafell - Free user manual and instructions
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| Product type | Lamello / flush trim router |
| Brand | Mafell |
| Model | KF 1000 |
| Power input | 1000 W |
| Rated voltage | 230 V~, 50 Hz |
| Rated current | 4.6 A |
| No-load speed | 4,000 - 25,000 min⁻¹ |
| Speed adjustment | Electronic progressive via knob |
| Tool holder | Collet chuck Ø 8 mm (standard) |
| Tool shank diameter | 3 to 8 mm |
| Max. cutter diameter | 30 mm |
| Milling depth | Tool-free adjustment by rotating motor unit |
| Weight (without cable) | 2.1 kg |
| Dimensions (w × l × h) | 103 × 226 × 328 mm |
| Cable length | 4 m |
| Protection class | II (double insulation) |
| Sound pressure level | 71 dB(A) (uncertainty K=3 dB) |
| Sound power level | 82 dB(A) (uncertainty K=3 dB) |
| Standard equipment | Routing table, collet Ø 8 mm, wrench 17 mm, case, instructions, safety booklet |
| Intended use | Flush trimming and profiling of wood, plastic and similar materials |
| Dust extraction system | Integrated dust hood, connection Ø int. 29 mm |
| Spindle lock | Yes, by push button |
| Spare parts and repairability | Replaceable carbon brushes (125-150 h), lifetime lubricated bearings, original MAFELL parts |
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USER MANUAL KF 1000 Mafell
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Close-up of a black industrial sewing machine (no visible text or symbols)MAF02286/a
WARNUNG
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.
AVERTISSEMENT
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Mechanical device with labeled parts, no visible text or symbolsMAF02288/a

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Mechanical device with numbered parts (7, 8, 9, 10) shown in a mechanical assembly (no text or symbols on the device itself)MAF02289/a

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| U_s [V] | n [min⁻¹] | | ------- | --------- | | 0 | 4000 | | 1 | 6000 | | 2 | 8000 | | 3 | 10000 | | 4 | 12000 | | 5 | 14000 | | 6 | 16000 | | 7 | 18000 | | 8 | 20000 | | 9 | 22000 | | 10 | 25000 || KF 1000 | |
| 1 | 4.000 min ^-1 |
| 2 | 7.500 min ^-1 |
| 3 | 12.000 min ^-1 |
| 4 | 16.000 min ^-1 |
| 5 | 21.000 min ^-1 |
| 6 | 25.000 min ^-1 |
GB - EC Declaration of Conformity
We herewith confirm that the machine KF 1000 complies with the EU directives quoted. The standards listed were used for design and construction. Empowered person for the configuration of the technical documents: Mafell AG
| 1 | Signs and symbols | 15 |
| 2 | Product information | 15 |
| 2.1 | Manufacturer's data | 15 |
| 2.2 | Machine identification | 15 |
| 2.3 | Technical data | 16 |
| 2.4 | Emissions | 16 |
| 2.5 | Scope of supply | 16 |
| 2.6 | Use according to intended purpose | 17 |
| 2.7 | Residual risks | 17 |
| 3 | Safety instructions | 17 |
| 4 | Setting / Adjustment | 18 |
| 4.1 | Mains connection | 18 |
| 4.2 | Selection of tools | 18 |
| 4.3 | Tool change | 19 |
| 5 | Operation | 19 |
| 5.1 | Initial operation | 19 |
| 5.2 | Switching on and off | 19 |
| 5.3 | Setting the digging depth | 20 |
| 5.4 | Additional limit stop | 20 |
| 5.5 | Collets | 20 |
| 5.6 | Extraction hood | 20 |
| 6 | Service and maintenance | 21 |
| 6.1 | Storage | 21 |
| 7 | Troubleshooting | 21 |
| 8 | Optional accessories | 21 |
| 9 | Exploded drawing and spare parts list | 21 |
1 Signs and symbols

This symbol is found in all places where you will find information for your safety.
Non-compliance with these instructions may result in very serious injuries.

This symbol indicates a potentially hazardous situation.
If this situation is not avoided, the product or objects in its vicinity may get damaged.

This symbol indicates tips for the user and other useful information.
2 Product information
in respect of machines with item number 91C501, 91C520, 91C521
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 Machine identification
All details required for machine identification are available on the attached rating plate.

Protection class II

CE symbol to document compliance with the basic safety and health requirements according to Appendix I of the Machinery Directive.

For EU countries only
Do not dispose of electric tools together with household waste material! In accordance with the European directive 2002/96/EC on waste electrical and electronic equipment and transposition into national law, obsolete electrical tools must be collected separately and recycled in an environmentally-compatible manner.

To reduce the risk of injury, please read the operating instructions.
2.3 Technical data
| Universal motor, radio and TV interference suppressed | 230 V~, 50 Hz |
| Power input (nominal load) | 1000 W |
| Current at nominal load | 4.6 A |
| Idling speed | 4,000 - 25,000 rpm |
| Tool holding fixture with collet ø | 8 mm (0 5/16 in.) |
| Tool shank maximum | 8 mm (0 5/16 in.) |
| Tool shank minimum | 3 mm (0 1/8 in.) |
| Milling cutter ∅, maximum | 30 mm (1 3/16) |
| Weight without mains cable | 2.1 kg (4.63 lbs) |
| Length of connecting cable | 4 m (13 1/8 ft.) |
| Dimensions (W x L x H) | 103 x 226 x 328 mm (4 1/16 x 8 57/64 x 12 29/32) |
2.4 Emissions
The declared noise emission values have been measured in accordance with DIN EN 62841-1 and may be used for comparing the tool with another and also in a preliminary assessment of exposure.

Danger
The noise emissions during actual use of the power tool can differ from the declared values depending on the ways in which the tool is used especially what kind of workpiece is processed.
Always wear hearing protection, even when the power tool is running idle in addition to the trigger time!
2.4.1 Noise emission specifications
Noise emission values determined according to EN 62841:
| Sound pressure level | L_PA = 71 dB (A) |
| Uncertainty | K_PA = 3 dB (A) |
| Sound power level | L_PA = 82 dB (A) |
| Uncertainty | K_PA = 3 dB (A) |
The noise measurement was done without tool at idling speed.
2.5 Scope of supply
Edge cutter KF1000 complete with:
1 milling table, complete
1 collet ∅ 8 mm OZ8
1 open-ended spanner AF 17
1 carrying case
1 operating manual
1 folder "Safety Instructions"
2.6 Use according to intended purpose
The KF1000 is exclusively suitable for flush milling and profile milling of wood, plastics and similar materials in conjunction with the complete milling table included in the supply.
Any other use than described above is not permissible. The manufacturer cannot be held liable for any damage arising from such other use.
In order to use the machine as intended, comply with the operating, maintenance, and repair instructions specified by Mafell.
Please take into account the milling motor capacity at maximum tool diameter and anticipated machining depth.
Keep power tools away from rain or moisture. The penetration of water into a power tool increases the risk of electric shock.
The appliance is not designed for non-stop industrial operation. The maximum speed can be referenced in chapter 2.3 Technical data.
2.7 Residual risks

Danger
Even if used in accordance with its intended purpose and despite conforming with the safety instructions, residual risks caused by the intended use that can lead to health consequences will always remain.
- Breakage of the tools and risk of the tools or parts of them being hurled away.
- Touching live parts with the housing open and the mains plug not removed.
- Hearing can be impaired when working for long periods without ear protectors.
- Emission of hazardous or potentially explosive dusts (all types) during longer lasting operation without extraction. Please note the safety data sheet of the material to be machined.
3 Safety instructions

Danger
Always observe the following safety instructions and the safety regulations applicable in the respective country of use!
General instructions:
- Children and adolescents must not operate this machine. This rule does not apply to young persons receiving training and being supervised by an expert.
- Never work without the protection devices stipulated for the respective operating sequence and do not effect any modifications on the machine that could impair safety.
- Damaged cables or plugs must be immediately replaced. Replacement may only be carried out by MAFELL or an authorised MAFELL service workshop in order to avoid safety hazards.
- Avoid sharp bends in the cable. Do not wind the cable around the milling motor especially when transporting and storing the milling motor.
Machine-specific safety instructions:
- Only hold the power tool by the isolated handles, as the milling tool could encounter and cut into its own connecting cable. Cutting accessory contacting a "live" wire may make exposed metal parts of the power tool "live" and could give the operator an electric shock.
- Only operate the machine with a correctly fitted milling table and extraction hood.
- Only use milling tools approved for at least 25,000 rpm according to EN 847.
- Ensure that the milling tool is firmly seated and check that it is running smoothly.
Do not use:
- Damaged tools or tools that have changed their shape.
- Blunt tools due to the excessive motor load.
- Tools that are not suitable for the milling motor speed during idling.
Instructions on the use of personal protective equipment:
- Always wear ear protectors during work.
- Always where a dust mark during work.
- Always wear protective goggles during work.
Instructions on operation:
- Do not reach with your hands into the danger zone of the tool.
- Examine the workpiece for foreign objects.
- Never support the workpiece in your hand or over your leg. Secure the workpiece against a sturdy support.
Instructions on service and maintenance:
- Regular cleaning of the milling motor is an important safety factor.
- Only original MAFELL spare parts and accessories may be used. Otherwise, the manufacturer will not accept any warranty claims and cannot be held liable.
4 Setting / Adjustment
4.1 Mains connection
Prior to initial operation, make sure that the mains voltage agrees with the operating voltage stated on the milling motor's rating plate.
4.2 Selection of tools
Only use the collets/adapter sleeves and suitable milling cutters listed in chapter 8 "Optional accessories".
4.3 Tool change

Danger
Pull the power plug during all service work.

Wear protective gloves during a tool change. The insertion tool can get very hot during longer operation and/or the insertion tool's cutting edges are sharp.
The spindle 1 (Fig. 1) of the milling motor is equipped with a precision collet 2 (Fig. 1) to hold the tools. Tightening and releasing the unit nut 3 (Fig. 1) is made easy with a spindle lock 4.
Proceed as follows for the tool change:
- Lock the spindle 1 (Fig. 1) to unclamp the tool by pressing the locking button 4 (Fig. 1).
- Detach union nut 3 with an open-ended spanner AF 17.
- Pull off the tool to the front.
- Push the new tool into the tool holding fixture up to the limit stop.
- Check the tool's seat.
- Spindle 1 is locked when the tool is clamped.
- Tighten union nut 3 with the open-ended spanner
5 Operation
5.1 Initial operation
Personnel entrusted to work with the milling motor must be made aware of the operating manual, calling particular attention to the chapter “Safety instructions”.
Mount the milling cutter and the milling table before you put the machine into operation.
5.2 Switching on and off
- Switching on: Push the switch 5 (Fig. 1) forward until it engages.
- Switching off: Push onto the rear end of the switch. The switch jumps into off position.
The built-in electronic system provides for jerk-free acceleration when the machine is switched on and under load readjusts the speed to the fixed setting.
In addition, this electronic system reduces the motor output in case of an overload, i.e. the spindle stops. Switch the machine off then. Remove the cause (reduce feed speed, use sharp tool, etc.) and continue to work.
With the setting wheel 6 (Fig. 2) you can adjust the speed continuously. Appropriate speed values at the different levels can be referenced in the table on page 4.
5.3 Setting the digging depth
The milling depth can be adjusted continuously by turning the motor unit in relation to the milling table.
- Release the clamping lever 7 (Fig. 4).
- Turn the motor unit to adjust the milling depth
- Clockwise turning = increase milling depth
- Anti-clockwise turning = decrease milling depth
- Re-tighten the tension lever

The scale on the milling attachment can be used for fine adjustment.
5.4 Additional limit stop

The additional limit stop 8 (Fig. 3) can be used for machining corners.
- Pull the additional limit stop 8 (Fig. 3) from its bracket and insert it in the base plate. (Fig. 4)
5.5 Collets

Danger
To protect the thread, only screw the union nut 3 (Fig. 1) lightly onto the spindle 1, but do not tighten when no tool is inserted. Collet 2 could get pressed together too much and be damaged in the process.
- Always use the correct tool size for the respective collet.
- Oil the collet a little at the beginning and after longer use.
- Unscrew the union nut 3 with the collet 2.
- Tilt out the collet 2 to the side.
- If the collet is jammed, loosen it with a rubber hammer by a light blow from behind.
5.6 Extraction hood
Always use the extraction hood 9 while working with the tool (Fig. 4).
Connect the machine to a suitable external dust extractor during all work generating a considerable amount of dust. The air velocity must be at least 20 m/s (65.6 ft / sec.).
The internal diameter of hose connector 10 (Fig. 4) is 29 mm (1 9/64 in.).
The extraction hood is equipped with a thrust ring brake for milling cutters with thrust ring.
On milling cutters without thrust ring, the brake can be removed by pulling the spring-loaded brake pin upwards and off.
To reactivate the brake, press the spring-loaded brake pin into the bracket provided until it engages.
6 Service and maintenance

Danger
Pull the power plug during all service work.
MAFELL machines are designed to be low in maintenance.
Replace the carbon brushes at the latest after 125 - 150 operating hours. The spare parts can be referenced in chapter 9.
The ball bearings used are greased for life. When the machine has been in operation for a longer period of time, we recommend to hand the machine in at an authorised MAFELL customer service shop for inspection.
6.1 Storage
If the power tool is not used for a longer period of time, it has to be carefully cleaned. Spray bright metal parts with a rust inhibitor.
7 Troubleshooting

Danger
Determining the causes for existing defects and eliminating these always requires increased attention and caution. Pull the mains plug beforehand!
Some of the most frequent defects and their causes are listed in the following chart. In case of other defects, please contact your dealer or the MAFELL customer service directly.
| Defect | Cause | Elimination |
| Machine cannot be switched on | No mains voltage | Check power supply |
| Mains fuse defective | Replace fuse | |
| Carbon brushes worn | Take the machine to a MAFELL customer service shop | |
| Machine stops while working | Mains failure | Check mains back-up fuses |
| Overload | Reduce feed speedUse sharp tool |
8 Optional accessories
- Collet ∅ 6 mm OZ8 + union nut
Order No. 093826
- Collet ∅ 8 mm OZ8 + union nut
Order No. 093825
- Face-milling cutter ø 19 mm
Order No. 090282
9 Exploded drawing and spare parts list
The corresponding information in respect of spare parts can be found on our homepage: www.mafell.com
Sommaire
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| GARANTIEGegen Vorlage der Garantieunterlage (Original-Kaufbeleg) werden innerhalb der jeweils gültigen Gewährleistungsregelungen kostenlos alle Reparaturen ausgeführt, die nach unseren Feststellungen wegen Material-, Bearbeitungs- und Montagefehlern erforderlich sind. Verbrauchs- und Verschleißteile sind hiervon ausgeschlossen. Hierzu muss die Maschine bzw. das Gerät frachtfrei an das Werk oder an eine MAFELL-Kundendienststelle geschickt werden. Vermeiden Sie, die Reparatur selbst zu versuchen, da dadurch der Garantieanspruch erlischt. Für Schäden, die durch unsachgemäße Behandlung oder durch normalen Verschleiß entstanden sind, wird keine Haftung übernommen. |
| WARRANTYUpon presentation of the warranty document (original invoice), we will carry out all repairs free of charge in accordance with the applicable warranty provisions, processing and mounting faults free of charge on presentation of this properly filled-in Guarantee Certificate and your original receipt. This is not valid for consumables and wearing parts. For this purpose, the machine or the appliance is to be forwarded freight paid to our plant or to an authorized MAFELL repair service. Refrain from trying to carry out the repairs yourself as otherwise your warranty claim will become extinct. We do not accept any liability for any damage resulting from improper handling or normal wear. |
| GARANTIESur présentation de cette carte de garantie, duement remplie par votre fournisseur et accompagnée de l'original de la pièce justifiant l'achat, nous effectuerons gratuitement toutes les réparations faisant l'objet d'un recours en garantie pendant la période indiquée, de la construction ou de la fabrication, à l'exclusion des pièces de consommation et d'usure. La machine ou l'appareil doit être pour cela expédié franco de port à notre usine ou à un atelier de service après-vente MAFELL. Évitez de procéder vous-mêmes à toute réparation, ceci périmant tout recours en garantie par la suite. Nous déclinons toute responsabilité en cas de dommages découlant d'une manipulation non conforme ou d'une usure normale. |
| GARANZIADietro presentazione del presente certificato di garanzia, regolarmente compilato, insieme alla ricevuta originale, vengono eseguite gratuitamente tutte le riparazioni necessarie riscontrate dai nostri accertamenti, entro il periodo di garanzia vigente, dovuti a difetti di materiale, di lavorazione o di montaggio. Da ciò sono esclusi pezzi di consumo e pezzi soggetti ad usura. A questo scopo la macchina ovvero l'apparecchio (eletrico) va spedito franco di porto allo stabilimento oppur e a d un punto di assistenza clienti della MAFELL. Evitate di tentare Voi stessi di effettuare la riparazione, altrimenti il diritto di garanzia viene revocato. Non ci assumiamo alcuna responsabilità per danni derivanti da trattamento non conforme o da normale usura. |
| GARANTIETegen vertoon van dit reglementair ingevuld garantie-bewijs, samen met het originele koopbewijs worden binnen de telkens geldige garantieregelingen gratis alle reparaties uitgevoerd, die volgens onzeconstateringen op grond van materiaal-, bewerkings- en montagefouten vereist zijn. Verbruik- en slijtagedelen zijn hiervan uitgesloten. Hiervoor moet de machine resp. het apparaat vrachtvrij naar de fabriek of naar een MAFELL-klantenservice worden gestuurd. Vermijdt u het de reparatie zelf uit te voeren, omdat daardoor de garantieclaim vervalt. Voor schade die door ondeskundige behandeling of door normale slijtage is ontstaan, wordt geen aansprakelijkheid aanvaardt. |
| GARANTÍAPresentando este documento de garantía (recibo original de compra), todas las reparaciones necesarias por defectos de material, errores de mecanizado o faltas de montaje en el marco de las reglamentaciones de la garantía concedida por parte del fabricante se efectuarán libre de gastos. Se excluyen sin embargo piezas fungibles o de desgaste. Para ello, entregue a porte pagado la máquina o el equipo a las fábricas del fabricante o a uno de los puntos de asistencia técnica de MAFELL. No realice nunca las tareas de reparación a cuenta propia. De lo contrario, caducará el derecho a garantía. No se asumirá responsabilidad alguna por los daños que se desprendan del uso inapropiado ni por el desgaste en el uso diario. |
| TAKUUTätä takuukuittia (alkuperäinen ostokuitti) vastaan suoritetaan voimassa olevan takuuajan sisällä maksutta kaikki korjaukset, jotka olemme todenneet tarpeellisiksi materiaali-, valmistus- ja asennusvirheistä johtuen. Käyttö- ja kuluvat osat ei kuulu takuupiriin. Korjausta varten kone tai laite on lähetettävä asianmukaisesti postitettuna joko tehtaalle tai johonkin MAFELL-asiakaspalveluun. Älä yritä korjata konetta itse, koska siinä tapauksessa takuu sammu. Takuu ei vastaa vahingoista, jotka johtuvat asiaankuulumattomasta käytöstä tai normaalista kulumisesta. |
| GARANTIMot uppvisande av kvitto utförs kostnadsfritt, under giltiga garantiåtaganden, alla reparationer som efter fastställande från vår sida kan härledas till material-, bearbetnings- eller monteringsfel. Förbruknings- och förslitningsdelar undantagna. Maskinen eller verktyget måste skickas fraktfritt till fabrik eller till MAFELLkundservice. Undvik att själv försöka utföra reparationen då detta leder till att garantianspråk förfaller. För skador som uppkommer på grund av felaktig behandling eller normalt slitage övertas inget ansvar. |
| GARANTIMod fremlæggelse af garantibeviset (original kvittering) ydes der gratis reparation af materiale-, fremstillings- og monteringsfejl, i henhold til de gældende garantibetingelser. Forbrugs- og sliddele udelukkes fra denne garanti. Hertil sendes maskinen/apparatet fragtfrit til producenten eller et Mafell-kundeserviceværksted. Hvis kunden selv forsøger at reparere maskinen, bortfalder garantien. Der overtages intet ansvar for beskadigelser, der opstår pga. uhensigtsmæssig brug eller normal slitage. |
| ГарантияПри предъявлении документации на гарантию (оригинальная квитанция) в соответствии с правилами о предоставлении гарантии мы бесплатно произведем все необходимые ремонты, которые по нашему определению необходимы в связи с дефектом материала, обработки и сборки. Это не относится к расходным материалам и изнашиваемым деталям. Для этого машина или устройство должно быть франко-фрахт отправлено на завод или мастерскую обслуживания клиентов фирмы MAFELL. Избегайте попыток самостоятельного ремонта, поскольку в этом случае гарантия аннулируется. Мы не несем ответственности на вред, причиненный в результате неправильного обращения или естественного износа. |
| GWARANCJAPo przedstawieniu gwarancji (oryginału dowodu zakupu) wykonane zostaną w ramach terminu gwarancji wszelkiego rodzaju naprawy, które według naszej oceny są konieczne z powodu błędów materialowych oraz błędów przy obróbce i montażu.Nie dotyczy to części zamienne i zużywalne. Prosimy o przesłanie maszyny wzgl. urządzenia na nasz koszt do zakładu lub serwisu MAFELL. Unikać dokonywania samodzielnych napraw, gdyż powoduje to utratę roszczeń gwarancyjnych. Nie przejmujemy odpowiedzialności za szkody powstałe w wyniku niefachowej obsługi lub normalnego zużycia. |
| ZÁRUKAPo předložení záručních podkladů (originální doklad o koupi) budou provedeny v rámci aktuálně platných pravidel pro poskytování záruky provedeny všechny opravy, které jsou podle našich zjištění požadovány z hlediska vad materiálu, zpracování a montáže. Díly podléhající používání a opotrebení jsou z tohoto vyjmuty. Navíc k tomu musí být stroj, případně přístroj zaslán vyplaceně do závodu nebo zákaznického servisu MAFELL. Nezkoušejte stroj opravovat sami, protože tím zaniká nárok na záruku. Záruky se nevztahují na škody vzniklé neodbornou manipulací nebo na ty, které vznikly v důsledku normálního opotrebování. |
| GARANCIJAOb priložitvi garancijske dokumentacije (originalni nakupni račun) bodo v okviru veljavnih garancijskih pogojev brezplačno opravljena vsa popravila, ki so po naši oceni potrebna zaradi napak v materialu, obdelavi in montażi. Porabni in obrabni deli so izvzeti iz tega določila. V ta namen morate stroj oz. napravo prosto voznine poslati v tovarno ali v pooblaščeno MAFELL servisno delavnico. Popravil ne skušajte opravljati samostojno, saj s tem ugasne pravica do garancije. Za škodo, ki nastane zaradi nestrokovnega ravnanja ali zaradi normalne obrabe, ne prevzemamo odgovornosti. |
| ZÁRUKAPo predložení záručného listu (originálneho dokladu o kúpe) budú všetky opravy, ktoré určíme ako nevyhnutné z dôvodu chýb materiálu, spracovania a montáže, wykonané bezplatne v rámci platných záručných predpisov. Spotrebné diely a diely podliehajúce opotrebeniu sú z toho vylúčené. K tomu sa musí zaslať stroj alebo prístroj bez dopravného do podniku alebo zákaznickeho servisu MAFELL. Vyhnite sa pokusom o samostatnú opravu, pretože tým stratíte nárok na záruku. Za škody spôsobené neodbornou manipuláciou alebo bežným opotrebovaním nepreberáme žiadnu zodpovednosť. |

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mafell creating excellenceMAFELL AG
Beffendorfer Straße 4, D-78727 Oberndorf / Neckar
Telefon +49 (0)7423/812-0
Internet:
E-Mail:
Fax +49 (0)7423/812-218
www.mafell.de
mafell@mafell.de