Mafell KF 1000 Operational manual

KF 1000
170645.0220/a
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
Originele gebruiksaanwijzing
38
Fresa de cantos
Manual de instrucciones original
46
Kulmajyrsin
Alkuperäiskäyttöohje
54
Kantfräs
Originalbruksanvisning
62
Kantfræser
Original driftsvejledning
70
Кромочный фрезер
Оригинальное руководство по эксплуатации
78
Frezarka krawędziowa
Tłumaczenie oryginalnej instrukcji obsługi
87
Hranová frézka
Původní provozní návod
95
Robni rezkalnik
Izvirna navodila za uporabo
103
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.
AVVERTENZA
Leggere tutte le avvertenze di sicurezza e le istruzioni. La mancanza del rispetto delle avvertenze di sicurezza e delle istruzioni possono
causare scossa elettrica, incendio e/o gravi lesioni. Conservare tutte le avvertenze di sicurezza e le istruzioni per il futuro.
WAARSCHUWING
Lees alle veiligheidsaanwijzingen en instructies. Nalatigheid bij het naleven van de veiligheidsinstructies en aanwijzingen kan elektrische
schok, brand en/of ernstige letsels veroorzaken. Bewaar alle veiligheidsaanwijzingen en instructies voor later gebruik.

ADVERTENCIA
Lea todas las indicaciones de seguridad e instrucciones. Si no se cumplen las indicacionesde seguridad e instrucciones, se pueden
producir descargas eléctricas, incendios y/o lesiones graves. Guarde todas las indicaciones de seguridad e instrucciones para el futuro.
VAROITUS
Lue kaikki turvaohjeet ja käyttöohjeet. Laiminlyönti turvaohjeiden ja käyttöohjeiden noudattamisessa voi aiheuttaa sähköiskun, tulipalon
ja/tai vakavia vammoja. Säilytä kaikki turvaohjeet ja käyttöohjeet tulevaisuuden varalle.
VARNING
Läs alla säkerhetsanvisningar och anvisningar. Underlåtenhet att följa säkerhetsanvisningar och anvisningar kan orsaka elstötar, brand
och/eller allvarliga personskador. Behåll alla säkerhetsanvisningar och anvisning för framtida användning.
ADVARSEL
Læs alle sikkerhedshenvisninger og instruktioner. En manglende overholdelse af sikkerhedshenvisningerne og instruktionerne kan føre til
elektrisk stød, brand og/eller alvorlige kvæstelser. Opbevar alle sikkerhedshenvisninger og instruktioner til fremtidig brug.
ПРЕДУПРЕЖДЕНИЕ
Прочитайте все правила и инструкции по технике безопасности. Несоблюдение этих правил и инструкций по технике
безопасности может привести к поражению электрическим током, возгоранию и/или другим серьезным травмам. Сохраните все
правила и инструкции по технике безопасности для дальнейшего использования.
OSTRZEŻENIE
Przeczytać wszystkie przepisy bezpieczeństwa i wskazówki. Zaniedbanie przestrzegania przepisów bezpieczeństwa i wskazówek może
prowadzić do porażenia prądem, pożaru i/lub ciężkich zranień. Zachować wszystkie przepisy bezpieczeństwa i wskazówki na przyszłość.
UPOZORNĚNÍ
Přečtěte si všechna bezpečnostní upozornění a pokyny. Zanedbání bezpečnostních upozornění a pokynů může způsobit zásah
elektrickým proudem, požár a/nebo vážná zranění. Všechna bezpečnostní upozornění a pokyny si ponechejte pro pozdější použití.
OPOZORILO
Preberite vsa varnostna opozorila in napotke. Neupoštevanje varnostnih opozoril in napotkov lahko povzroči udar električnega toka, požar
in/ali hude telesne poškodbe. Vsa varnostna opozorila in napotke shranite za prihodnjo uporabo.

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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
1Signs and symbols .........................................................................................................15
2Product 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................................................................................16
2.7 Residual risks ................................................................................................................. 17
3Safety instructions ..........................................................................................................17
4Setting / Adjustment .......................................................................................................18
4.1 Mains connection ...........................................................................................................18
4.2 Selection of tools ............................................................................................................ 18
4.3 Tool change....................................................................................................................18
5Operation........................................................................................................................19
5.1 Initial operation ............................................................................................................... 19
5.2 Switching on and off .......................................................................................................19
5.3 Setting the digging depth................................................................................................19
5.4 Additional limit stop ........................................................................................................19
5.5 Collets ............................................................................................................................20
5.6 Extraction hood .............................................................................................................. 20
6Service and maintenance...............................................................................................20
6.1 Storage...........................................................................................................................20
7Troubleshooting..............................................................................................................20
8Optional accessories ......................................................................................................21
9Exploded drawing and spare parts list ...........................................................................21

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1Signs and symbols
This symbol appears at places where you will find instructions for your own
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.
2Product 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
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 values stated are emission levels. Although there is a correlation between emission and imission level, it
cannot be reliably derived from this whether additional precautions are necessary. Factors influencing the
current immission level existing at the workplace comprise the duration of exposure, the room characteristic,
other sources of noise, etc. such as e.g. the number of machines and other adjacent machining operations. In
addition, the permissible immission level may differ from country to country. This information is nevertheless
suitable for providing the machine user with an improved assessment of the hazard and risk.
2.4.1 Noise emission specifications
Noise emission values determined according to DIN EN ISO 3744:
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 face-milling cutter ø 19 mm
1 collet Ø 8 mm
1 open-ended spanner AF 17
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.

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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 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.
3Safety 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 power tool especially when transporting
and storing the power tool.
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.

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- 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 power tool 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 power tool 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.
4Setting / Adjustment
4.1 Mains connection
Prior to initial operation, make sure that the mains voltage agrees with the operating voltage stated on the
machine'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.

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Check the tool’s seat.
Spindle 1 is locked when the tool is clamped.
Tighten union nut 3 with the open-ended spanner
5Operation
5.1 Initial operation
Personnel entrusted to work with the power tool 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)

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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.
6Service 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.
7Troubleshooting
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.

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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
8Optional accessories
- Collet Ø 3 mm
Order No. 093731
- Collet Ø 4 mm
Order No. 093732
- Collet Ø 6 mm
Order No. 093733
- Collet Ø 8 mm
Order No. 093734
- Collet Ø 1/8“ (3.175 mm)
Order No. 093735
- Collet Ø 1/4“ (6.35 mm)
Order No. 093736
- Collet Ø 3 mm + union nut
Order No. 093737
- Collet Ø 1/8“ (3.175 mm) + union nut
Order No. 093738
- Union nut
Order No. 093729
- Reducing sleeve ø3 mm
Order No. 207944
- Reducing sleeve ø1/8“(3.175)
Order No. 207945
- Reducing sleeve ø4 mm
Order No. 207949
- Reducing sleeve ø6 mm
Order No. 207946
- Collet adapter incl. union nut
Order No. 207943
- Face-milling cutter ø 19 mm
Order No. 090282
9Exploded drawing and spare parts list
The corresponding information in respect of spare parts can be found on our homepage: www.mafell.com