Mafell KF 1000 Operational manual

KF 1000
170645.0223/e
Kantenfräse Originalbetriebsanleitung 6
Edge cutter Translation of the original operating manual 14
Affleureuse Traduction de la notice d'emploi originale 22
Fresatrice per bordi Traduzione delle istruzioni per l'uso originali 30
Kantfreesmachine Vertaling van de originele gebruiksaanwijzing 38
Fresa de cantos Traducción del manual de instrucciones original 46
Kulmajyrsin Käännös alkuperäiskäyttöohjeesta 54
Kantfräs Översättning av originalbruksanvisningen 62
Kantfræser Oversættelse af den originale betjeningsvejledning 70
78
86
Hranová frézka 94
Robni rezkalnik Prevod izvirnih navodil za uporabo 102
110
WARNUNG
Lesen Sie alle Sicherheitshinweise und Anweisungen. Versäumnisse bei der Einhaltung der Sicherheitshinweise und Anweisungen können
elektrischen Schlag, Brand und/oder schwere Verletzungen verursachen. Bewahren Sie alle Sicherheitshinweise und Anweisungen für die
Zukunft auf.
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.
AVERTISSEMENT
Veuillez lire toutes les consignes de sécurité et instructions. Tout non-respect des consignes de sécurité et instructions risque d'être à
l'origine de décharges électriques, d'incendies et/ou de blessures graves. Conservez toutes les consignes et instructions pour pouvoir les
relire à tout moment.

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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

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English
Table of Contents
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

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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 [phone], Fax +49
(0)7423/812-218, e-mail: [e-mail]
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.

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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 Ø, 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 ist 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 LPA = 71 dB (A)
Uncertainty KPA = 3 dB (A)
Sound power level LPA = 82 dB (A)
Uncertainty KPA = 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 Ø 8 mm OZ8
1 open-ended spanner AF 17
1 carrying case
1 operating manual
1 folder "Safety Instructions"

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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.

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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

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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
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.
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
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.

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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.

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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 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
9 Exploded drawing and spare parts list
The corresponding information in respect of spare parts can be found on our homepage: www.mafell.com

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GARANTIE
Gegen 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.
WARRANTY
Upon 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.
GARANTIE
Sur 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
ié 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.
GARANZIA
Dietro 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 (elettrico) 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.
GARANTIE
Tegen 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.
GARANTÍA
Presentando 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.
TAKUU
Tätä 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 takuupiiriin. Korjausta varten
kone tai laite on lähetettävä asianmukaisesti postitettuna joko tehtaalle tai johonkin MAFELL-asiakaspalveluun. Älä yritä korjata konetta itse,
koska siinä tapauksessa takuu sammuu. Takuu ei vastaa vahingoista, jotka johtuvat asiaankuulumattomasta käytöstä tai normaalista
kulumisesta.
GARANTI
Mot 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.