KF 1000 - Milling machine Mafell - Free user manual and instructions

USER MANUAL KF 1000 Mafell

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

All details required for machine identification are available on the attached rating plate.

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.-16-

Universal motor, radio and TV interference suppressed

Current at nominal load

4,000 - 25,000 rpm Tool holding fixture with collet ø

Length of connecting cable

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 ist running idle in addition to the trigger time!

Noise emission values determined according to EN 62841: Sound pressure level

= 71 dB (A) Uncertainty

= 3 dB (A) Sound power level

= 82 dB (A) Uncertainty

The noise measurement was done without tool at idling speed.

Edge cutter KF1000 complete with: 1 milling table, complete 1 collet Ø 8 mm OZ8 1 open-ended spanner AF 17 1 carrying case 1 operating manual 1 folder "Safety Instructions"-17-

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

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.-18- 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”.-19-

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.-20-

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)

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.

• 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.

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.-21- 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

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.

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 speed Use sharp tool

8 Optional accessories - Collet Ø 6 mm OZ8 + union nut Order No. 093826 - Collet Ø 8 mm OZ8 + union nut Order No. 093825

- Face-milling cutter ø 19 mm Order No. 090282

= 71 dB (A) Negotovost

= 82 dB (A) Negotovost