PF 1200 EPlus - Milling machine FESTOOL - Free user manual and instructions

USER MANUAL PF 1200 EPlus FESTOOL

EC-Declaration of Conformity. We declare under our sole responsibility that this product is in conformity with all relevant provisions of the fol- lowing directives including their amendments and complies with the following standards:

2.1 General power tool safety warnings

WARNING! Read all safety warn- ings, instructions, illustrations and specifications provided with this power tool. Failure to follow all instructions listed below may result in electric shock, fire and/or serious injury. Save all warnings and instructions for future reference. The term „power tool“ in the warnings refers to your mains-operated (corded) power tool or battery-operated (cordless) power tool.

2.2 Tool-specific safety warnings for milling

tools Milling procedures

DANGER! Keep hands away from cutting area and the milling tool. Keep your sec- ond hand on auxiliary handle, or motor housing. If both hands are holding the milling tool, they cannot be cut by the tool. b) Do not reach underneath the workpiece. The guard cannot protect you from the tool below the workpiece. c) Adjust the milling depth to the thickness of the workpiece. Less than a full tooth of the tool should be visible below the workpiece. d) Never hold the workpiece in your hands or across your leg while milling. Secure the workpiece to a stable platform. It is important to support the work properly to minimize body exposure, binding, or loss of control. e) Hold the power tool by insulated gripping sur- faces, when performing an operation where the milling tool may contact hidden wiring or its own cord. Contact with a „live“ wire will also make exposed metal parts of the power tool „live“ and could give the operator an electric shock. f) When milling, always use a straight edge guide. This improves the accuracy of cut and reduces the chance of binding. g) Always use mounting tools with correct size and shape (diamond versus round) of arbour holes. Tools that do not match the mounting hardware of the milling tool will run eccentri- cally, causing loss of control. h) Never use damaged or incorrect blade wash- ers or bolt. The washers and bolt were specially designed for your milling tool, for optimum per- formance and safety of operation. Kickback causes and related warnings – kickback is a sudden reaction to a pinched, bound or misaligned mounting tool, causing an uncontrolled milling tool to lift up and out of the workpiece toward the operator; – when the milling tool is pinched or jammed tightly by the kerf closing down, the milling tool stalls and the motor reaction drives the unit rapidly back toward the operator; – if the milling tool becomes twisted or misaligned in the groove, the teeth at the back edge of the milling tool can dig into the top surface of the material causing the milling tool to climb out of the kerf and jump back toward the operator. Kickback is the result of misuse and/or incorrect operating procedures or conditions and can be avoided by taking proper precautions as given below. a) Maintain a firm grip with both hands on the milling tool and position your arms to resist kickback forces. Position your body to either13 side of the tool, but not in line with the tool. Kickback could cause the milling tool to jump backwards, but kickback forces can be con- trolled by the operator, if proper precautions are taken. b) When the tool is binding, or when interrupting a cut for any reason, release the trigger and hold the tool motionless in the material until the tool comes to a complete stop. Never attempt to remove the milling tool from the work or pull the milling tool backward while the tool is in motion or kickback may occur. Investigate and take corrective actions to eliminate the cause of binding. c) When restarting a milling tool in the work- piece, centre the tool in the kerf so that the tool teeth are not engaged into the material. If a tool binds, it may walk up or kickback from the workpiece as the milling tool is restarted. d) Support large panels to minimise the risk of pinching and kickback. Large panels tend to sag under their own weight. Supports must be placed under the panel on both sides, near the line of cut and near the edge of the panel. e) Do not use dull or damaged tools. Unsharpened or improperly set tools produce narrow kerfs causing excessive friction, binding and kickback. f) Tool depth and bevel adjusting locking levers must be tight and secure before milling. If tool adjustment shifts while milling, it may cause binding and kickback. g) Use extra caution when milling into existing walls or other blind areas. The protruding tool may cut objects that can cause kickback. Function of the lower guard a) Check the function of the springs for the lower guard. If the lower guard or springs show any signs of a defect, have the milling tool serviced before using it again. Damaged parts, sticky deposits or accumulated chips may result in delayed operation of the lower guard.

2.3 Further safety warnings

Wear suitable protective equip- ment such as ear protection, safety goggles, a dust mask for work which generates dust, and protective gloves when working with raw materials and when changing tools. – This electric power tool cannot be installed in a work bench. The electric power tool may become unsafe and cause serious accidents if installed in benches from other manufacturers or self-manufactured work benches. – Never place your hands into the chip ejector. You may injure yourself on rotating parts. – Wait until the power tool stops completely until placing it down. The tool can become entangled and lead to a loss of control of the power tool. – Ensure that the milling tool is firmly seated and check that it runs smoothly. – Do not use the tool for overhead work. – Harmful/toxic dust may be produced during your work (e.g. paint containing lead, certain types of wood and metal). Inhaling or coming into contact with this dust may represent a hazard for operating personnel or persons in the vicinity. Comply with the safety regulations that apply in your country. Ensure that enclosed spaces are adequately ventilated.

2.4 Noise and vibration information

Typically, the noise levels that are determined in accordance with EN 62841 (see EC declaration of conformity) are as follows: Sound-pressure level L

(vector sum for three directions) and uncertainty K measured in ac- cordance with EN 62841 (see EU Declaration of Conformity): Routing a Dibond® panel a

= <2.5 m/s² K = 1.5 m/s² The specified emissions values (vibration, noise) – are used to compare machines. – They are also used for making preliminary estimates regarding vibration and noise loads during operation. – They represent the primary applications of the power tool.14 CAUTION 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. Identify safety measures to protect the operator that are based on an estimation of exposure in the actual conditions of use (taking account of all parts of the operat- ing cycle such as the times when the tool is switched off and when it is running idle in addition to the trigger time). 3 Intended use The PF 1200 E is used to route grooves into composite plates made from aluminium, plastic (Alucubond®, Dibond®). Only use power tools with attached dust extractor. Only insert milling tools with the correct dimen- sions. Do not use abrasive discs. Only a Festool routing tool in accordance with EN 847-1 may be used. Only rout materials for which the router has been designed. This power tool may only be used by experts or instructed persons. The user is liable for damage and ac- cidents caused by improper and non- intended use. 4 Power supply and start-up The mains voltage must correspond to the specification on the rating plate. Switch (4.2) serves as an On/Off switch (press = ON, release = OFF). The switch can only be acti- vated after the switch lock (4.1) has been pushed up. Activating the switch lock simultaneously locks the plunging equipment and the milling unit can be moved down against the spring force. This causes the milling tool to emerge from the pro- tective cover. Only guide the tool against the workpiece when it is switched on. When the tool is lifted, the milling unit springs back into the starting position. 5 Tool settings Always remove the power supply plug from the socket before carrying out any work on the tool.

The sensor remains on the workpiece while it is being routed. Its function is to determine the cut- ting depth. Festool offers sensors for all the usual plate thicknesses. Changing the sensor – Press the screws (1.1) and turn them to the left. – Open the flap (1.2). – Unscrew the four screws (1.4). – Replace the jockey roller (1.5). – Tighten the four screws (1.4). – Close the flap (1.2). – Press the screws (1.1) and turn them to the right until they latch into place.

5.2 Depth stop (4.5)

When the sensor is on the workpiece, i.e. in working position, there must be a gap of 0.3 mm between the depth stop (4.5) and the stop plate (4.4). This limits the cutting depth, and prevents the tool from tilting to the side while work is in progress. This would happen if one side of the tool moved away from the guide rail. Use a screwdriver to adjust the three screws on the rotating depth stop. The screws have been set for plate thickness of 3 mm, 4 mm and 6 mm in the factory.

– Press the screws (1.1) and turn them to the left. – Open the flap (1.2). – Press the spindle stop (2.1) and turn the tool (2.4) until the spindle stop latches into place; keep the spindle stop pressed in. – Open the screw (2.2). – Remove the tool (2.5) and sensor (2.4). – Clean the contact surface between the tool flange, the tool, and the sensor; insert the new tool with the sensor.

The direction of rotation on the tool must be the same as the direction of rotation of the tool (2.3). – Tighten the screw (2.2) and let go of the spindle stop – Close the flap (1.2).15 – Press the screws (1.1) and turn them to the right until they latch into place.

Always connect the tool to a dust extrac- t or. You can connect a Festool extractor with an ex- tractor hose diameter of 36 mm to the extractor connector (4.8). 6 Electronics The PF 1200 E features full-wave electro- nics with the following properties: Smooth start-up The smooth start-up ensures the milling tool starts up jolt-free. Speed adjustment You can regulate the speed steplessly between 2000 and 5700 min

using the adjusting wheel (4.3). We recommend the following position in the adjusting wheel (4.3): 5-6. Constant speed The pre-selected speed remains constant wheth- er the tool is in operation or in neutral position. Temperature control To prevent overheating, the safety electronics switches the tool off when it reaches a critical motor temperature. Let the tool cool down for approx. 3-5 minutes before using it again. The tool requires less time to cool down if it is running, i.e. in neutral position. 7 Working with the tool Always secure the workpiece in such a manner that it cannot move while being cut. The tool must always be held with both hands by the designated handles (5.1, 5.2). Always push the tool forwards (5.3), never pull the tool backwards towards you. You can use the milling tool only in con- nection with the guide rail (3.1). Attach the guide rail to the workpiece as follows – The guide rail must extend at least 150 mm beyond either end of the workpiece. – Align the guide rail using the gauge mark (3.2). The front edge (3.4) shows the centre of the groove. – Secure both sides of the guide rail to the work- piece using two clamps (3.3). Metalworking The following precautions are to be taken when processing metals for safety rea- sons: – Pre-connect a residual current circuit-breaker (FI, PRCD). – Connect the tool to a suitable dust extractor. – Clean tool regularly of dust accumulations in the motor housing. Wear protective goggles. Route the groove as follows – Ensure that the sensor and depth stop are cor- rectly set for the workpiece thickness. – Place the tool on the guide rail in front of the edge of the workpiece. The mark (4.7) shows the centre axis of the milling tool. – Switch on the tool. – Move the tool downwards slowly until the stop plate (4.4) is resting on the depth stop (4.5). – Move the tool forward along the guide rail in order to route the groove. The gauge mark (4.6) shows the centre of the groove. – When the groove is complete, switch the tool off and swivel it upwards. Plunge-cut In the case of plunge cuts, a guide limiter (6.1) must be attached behind the tool be- cause of the danger of kickbacks. Position the tool on the guide limiter, hold securely with both hands and move it downwards very slowly. 8 Maintenance and care Always remove the power supply plug from the socket before carrying out any work on the tool. All maintenance and repair work which requires the motor casing to be opened may only be carried out by an authorised service centre. Always keep the tool and the ventilation slots clean. The tool is fitted with special motor brushes with an automatic cut-out. When the brushes become worn the power supply is shut off automatically and the tool comes to a standstill.16 A brake disc (1.3) decelerates the sensor to pre- vent it from being accelerated by the rotating tool and leaving marks behind on the workpiece. Replace the brake disc if its power decreases. Customer service and repair. Only through manufacturer or service work- shops: Please find the nearest address at: www.festool.com/service EKAT