Mafell ZK 115 Ec User manual

ZK 115 Ec
170184.0916/f
Zimmereikervenfräse Originalbetriebsanleitung 5
Carpentry bird's mouth
cutter
Original operating instructions 15
Fraiseuse de charpente Traduction de la notice d'emploi originale 25
Fresatrice intagli per
carpenteria
Istruzioni per l'uso originali 35
Kerffrees Originele gebruiksaanwijzing 45
Fresadora de ranuras en
V para carpinteros
Manual de instrucciones original 55
Ammattilaisen
viistourajyrsin
Alkuperäiskäyttöohje 65
Snickerispårfräs Originalbruksanvisning 74
Tømrerkærvfræser Original driftsvejledning 83
ACHTUNG!
Diese Betriebsanleitung enthält Hinweise, die für das sichere Arbeiten mit dieser Maschine wichtig sind.
Lesen Sie deshalb unbedingt diese Betriebsanleitung.
WARNING!
These operating instructions contain important information on safe working practices for this machine.
It is therefore essential that you read these operating instructions carefully.
ATTENTION !
Cette notice d'emploi contenant des indications importantes pour la sécurité du travail avec cette machine,
veuillez donc la lire impérativement.
ATTENZIONE!
Le presenti istruzioni per l’uso contengono avvertenze importanti per lavorare con sicurezza con questa macchina.
Per questo motivo è assolutamente necessario leggere le presenti istruzioni per l’uso con la dovuta accuratezza.
ATTENTIE!
Deze gebruiksaanwijzing omvat instructies die voor het veilige werken met deze machine belangrijk zijn.
Lees vandaar in ieder geval deze gebruiksaanwijzing.
¡ATENCIÓN!
Lea atentamente este manual de instrucciones, que contiene la información necesaria para garantizar la seguridad en el
trabajo con esta máquina.
HUOMIO!
Tämä käyttöohje sisältää ohjeita, jotka ovat tärkeitä koneen turvallisen käytön kannalta.
Lue käyttöohje sen vuoksi huolellisesti!
OBSERVERA!
Denna bruksanvisning innehåller anvisningar, viktiga för säkert arbete med denna maskin.
Läs därför denna bruksanvisning noga!
GIV AGT!
Denne driftsvejledning indeholder vigtige henvisninger om sikkerheden ved brug af maskinen.
Læs driftsvejledningen omhyggeligt.

-15-
English
Table of Contents
1 Signs and symbols ......................................................................................................... 16
2 Product information ........................................................................................................16
2.1 Manufacturer´s data ....................................................................................................... 16
2.2 Machine identification.....................................................................................................16
2.3 Technical data ................................................................................................................17
2.4 Noise emission specifications ........................................................................................17
2.5 Vibration specifications...................................................................................................17
2.6 Scope of supply..............................................................................................................18
2.7 Safety devices ................................................................................................................18
2.8 Use according to intended purpose................................................................................ 18
2.9 Residual risks ................................................................................................................. 18
3 Safety instructions .......................................................................................................... 18
4 Setting / Adjustment .......................................................................................................20
4.1 Mains connection ...........................................................................................................20
4.2 Tool change....................................................................................................................20
4.3 Insert change..................................................................................................................20
5 Operation........................................................................................................................ 21
5.1 Initial operation ...............................................................................................................21
5.2 Switching on and off ....................................................................................................... 21
5.3 Cutting bird's mouths......................................................................................................21
5.4 Cutting oblates, grooves and cones ............................................................................... 22
6 Service and maintenance...............................................................................................23
6.1 Machine..........................................................................................................................23
6.2 Tools............................................................................................................................... 23
6.3 Storage...........................................................................................................................23
7 Troubleshooting..............................................................................................................23
8 Special accessories........................................................................................................24
9 Exploded drawing and spare parts list ........................................................................... 24

-16-
1 Signs 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.
2 Product information
for machines with the item numbers 925001, 925020, 925021, 952022 oder 925025.
2.1 Manufacturer´s data
MAFELL AG, Postfach 1180, D-78720 Oberndorf / Neckar, Phone [phone], Fax [phone]-
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.

-17-
2.3 Technical data
Universal motor, radio and TV
interference suppressed
230 V~, 50
Hz 120 V~, 60
Hz
Power input (nominal load) 3000 W 2500 W
Current at nominal load 15,5 A 23,5 A
Speed of the output shaft when idle 4050 rpm
Speed of the output shaft with nominal
load
4050 rpm
Can be pivoted from 0 – 60°
Depth adjustment 0 - 83.5 mm (0- 3 29/100 in.)
Working tool
for bird's mouths: Cutter head Ø 150 x 115 mm
(5 29/32 x 4 17/32 in.)
nmax.= 5000 rpm
for flattening: Cutter head Ø 236 x 50 mm (9
29/100 x 1 97/100 in.)
nmax.= 5000 rpm
Cutter head Ø 190 x 80 mm (7
31/64 x 3 5/32 in.)
nmax.= 5000 rpm
Weight Machine with
stop without cutter head and
power cord
21,1 kg (46.5 lbs)
Cutter head Ø 150 x 115 mm 3.0 kg (6.6 lbs)
Cutter head Ø 236 x 50 mm 3.5 kg (7.7 lbs)
Cutter head Ø 190 x 80 mm 5.9 kg (13 lbs)
Cutting speed with nominal load: Cutter head Ø 150 x 115 mm 31.8 m/s (104 ft/sec.)
Cutter head Ø 236 x 50 mm 50.0 m/s (164 ft/sec.)
Cutter head Ø 190 x 80 mm 40.3 m/s (112 ft/sec.)
2.4 Noise emission specifications
Noise emission values determined according to EN 60745-1:
Sound power level Workplace-related emission value
Idling 108 dB (A) 97 dB (A)
Machining 109 dB (A) 98 dB (A)
The noise measurements were made with the standard cutter head included in delivery.
Workpiece: Spruce 140 x 140 x 2000 mm; Cutting depth: 20 mm; Guide without stop
The values stated do not take into consideration any possible series variances and are not suitable for
determining the rating levels, as these fluctuate in dependence on the time in service, the respective type of
machining and the environmental influences. The noise rating level can therefore only be determined on an
individual basis at the machine user's position.
2.5 Vibration specifications
The typical hand-arm vibration is 4.0 m/s2.

-18-
2.6 Scope of supply
Carpentry bird's mouth cutter ZK 115 Ec complete with:
1 parallel stop
1 bird's mouth cutter head Ø 150 x 115 mm (5 29/32 x 4 17/32 in.)
1 parallel stop
1 hex screwdriver
1 screwdriver Torx T 15
1 operating manual
1 folder “Safety Instructions”
2.7 Safety devices
Danger
These devices are required for the
machine's safe operation and may
not be removed or rendered
inoperative.
The machine is equipped with the following safety
devices:
-Upper stationary saw guard
-Lower retractable saw guard
-Upper retractable saw guard
-Large base plate
-Handles
-Index mechanism and brake
2.8 Use according to intended purpose
The MAFELL ZK 115 Ec carpentry bird's mouth cutter
is designed exclusively for working with wood.
For manual feeding use only tools that bear the MAN
and, if applicable, the BG test label.
The dimensioning of the cutting and flattening heads
used must correspond to the tools listed in this
operating manual.
The tool was manufactured in accordance with the
European norm EN 847-1.
Any other use than described above is not
permissible. The manufacturer cannot be held liable
for any damage arising from such other use.
So as to use the machine as intended, comply with
the operating, maintenance and repair instructions
specified by Mafell.
2.9 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.
-Touching the cutter head in the area of the start-up
opening.
-Touching the part of the cutter head that protrudes
below the workpiece when cutting.
-Machine backlash if the blade gets stuck in the
workpiece.
-Breakage and hurling out of the tool or parts of the
tool.
-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 wood dust when operating
the machine for longer periods of time without
extraction.
3 Safety instructions
Danger
Always observe the following safety
instructions and the safety
regulations applicable in the
respective country of use!

-19-
-Never work without the protective equipment
required for the work to be undertaken and never
modify anything on the machine that could impair
safety.
-Children and adolescents must not operate this
machine. This rule does not apply to young
persons receiving training and being supervised by
an expert.
-Before working with the machine, always check to
ensure that the protective and safety devices are
firmly in place and undamaged, that they work
faultlessly and that the the moving protective hood
works without getting stuck.
-Consider environmental influences. Do not expose
the machine to rain and avoid working in damp and
wet areas as well as near combustible liquids and
gasses.
-When operating the machine outdoors, use of an
earth-leakage circuit-breaker is recommended.
-Do not carry the machine by its cable and do not
use the cable to pull the plug out of the socket
outlet.
-Pay attention that the cable is protected against oil
and heat and is not pulled across sharp edges.
-Damaged cables or plugs must be immediately
replaced.
-Avoid sharp bends in the cable. Especially when
transporting and storing the machine, do not wind
the cable around the machine.
-Use only cutter heads with the specifications
indicated in this operating manual.
-Store the machine in a dry, locked place outside
the reach of children.
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:
-Provide for an unobstructed and slip-proof location
with adequate lighting.
-Unplug the power cord before changing tools,
making adjustments or rectifying faults (including
the removal of jammed chips).
-Do not work on workpieces which are too small or
too large for the capability of the machine.
-Install and fasten the cutter head properly. Use
sharp cutters and taper taps; dull cutters increase
the risk of kickout. Immediately replace damaged
cutters and taper taps and fasten them so that they
cannot become loose operation.
-The moving protective hood must not be blocked
when open.
-The switch may not be wedged.
-Before switching on the machine, always check
whether the cutter head is tightened and whether
the wrench and pin have been removed.
-If possible ensure that the workpiece is secured
from slippage, e.g. with tension clamps.
-Hold firmly onto the machine before switching it on.
-Begin cutting the workpiece only when the cutter
head reaches its full speed.
-Examine the workpiece for foreign objects. Do not
cut into metal parts, e.g. nails.
-Never reach under the workpiece while cutting
(risk of injury!).
-When cutting always have the connecting cable
behind the machine.
-An even forward feed when cutting extends the
service life of the cutting bit and the machine. Do
not cut backwards or by dipping.
-Remove the machine from the workpiece only
when the cutter head is at a standstill.
-Never touch the cutter head or reach into the chip
ejector while the machine is running. Always
switch off the machine before making adjustments
and ensure that the cutter head has come to a
standstill.
-Set the machine down only when the moving
protective hood is closed. Do not clamp the moving
protective hood or end guard, and ensure that they
work properly. Do not remove protective parts.
-The bird's head cutter may be used only outside or
in open areas, as effective extraction is not
possible.
Instructions on service and maintenance:
-Regularly cleaning the machine, especially the
adjusting devices and guides, constitutes an
important safety factor.

-20-
-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 commissioning make sure that the mains
voltage complies with the operating voltage stated on
the machine's rating plate.
4.2 Tool change
Danger
Always pull the power plug before
changing tools.
The maximum permissible speed
(indicated on the tool) must not be
exceeded!
The operating speed must not
exceed the maximum speed
indicated on the tool.
Ensure the correct direction of
rotation!
Clamp the tool so that it cannot
become loose during operation.
The blades must touch neither
each other nor clamping pieces.
Ensure that the machine is clean
before changing tools. Clamping
surfaces must be clean.
Lock the tool with pin 31 (fig. 1+2).
Use the hexagon screwdriver 29 to unscrew the
cylinder head screw anticlockwise, remove front
flange 27 and cutter head.
Clean chips and dusts off the spindle and
clamping surfaces and put the tool on. When
doing so ensure that both drive pins on the
spindle engage both bore holes on the tool.
Insert the cylinder head screw with flange and
tighten firmly with the hexagonal screwdriver.
Remove the pin and hexagonal screwdriver.
Danger
Idle speed of the output shaft =
4050 rpm, therefore install only
cutter heads with n ≥ 5000 rpm .
4.3 Insert change
Danger
Always pull the power plug before
making changes or adjustments.
Install and remove the cutters in
accordance with instructions in the
operating manual. Utmost caution
is mandatory!
Ensure clean clamping surfaces.
Observe the specified tightening
torques! The clamping screws must
be tightened only with the tools of
the same dimensions included in
delivery. No striking tools, levers,
extensions or other tools may be
used.
All blades must always be fitted in
order to prevent imbalance.
The cutter or flattening head must be fitted with
replaceable hard metal cutting inserts. Time-
consuming sharpening is unnecessary as the hard
metal cutting inserts need to be only turned or
replaced when the blades are dull.
Remove the tool from the machine (see section
4.2).
Loosen the screwed on hard metal cutting
inserts with the spanner included in delivery,
turn 90 degrees and tighten again° (4Nm) or,
after turning three times, replace with new
cutting inserts.
Clean all parts and the blade chamber in the
cutter head.
Aluminium tools may only be
deresinified with solvents which do
not corrode the aluminium.
Re-install the tool (see section 3.2).

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5 Operation
5.1 Initial operation
Personnel entrusted to work with the machine must
be made aware of the operating instructions, calling
particular attention to the chapter "Safety
instructions".
It is mandatory to check whether all safety devices
are attached and functional. This applies especially to
the ease of movement of the protective hood.
5.2 Switching on and off
Danger
Before switching the machine on
ensure that the cutter head can
move freely and that the moving
protective hood is closed.
Lead the connecting cable away to
the rear.
Take hold of the machine by the
handles.
Switch the machine on only when
the cutter head is not in contact
with the workpiece.
Switching on: First unlock the switch lock by
pressing the locking lever 12 (fig. 3). Then
actuate the shift lever 13 while pressing the
locking lever. As this is a switch without locking
device, the machine will only run for as long as
this gearshift lever is pressed.
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.
This electronic system also controls the motor upon
overload, e.g. the cutter head stays still. The machine
must then be unloaded until the cutter head has
reached its full speed. Then continue to cut at a lower
feed rate.
Switching off: Release the switch lever 13 to switch
the machine off. The built-in automatic break limits
the run-down time of the cutter head to approx. 5 s.
The switch lock takes effect automatically and
secures the bird's mouth cutter from inadvertantly
being switched on again.
5.3 Cutting bird's mouths
5.3.1 Mark bird's mouth
Angle and mark the two-sided bird's mouth mark at
the intersection. Pull the crevice A – B (fig. 4) over the
rafter.
5.3.2 Setting bird's mouth cutter
The following settings must be made before using the
machine:
Set the bird's mouth angle "α":
The cutter head can be pivoted from 0 – 60°.
Release the clamping lever 8 (fig. 5) and set the
angle value (e.g. 30°) on the angle scale.
Tighten the clamping lever; The clamping
position of the lever can be set by pulling it out
in a vertical direction.
Set the depth indicator:
The cutter depth indicator depends on the set
bird's mouth angle "α". The depth indicator 4
can therefore be set from 0 – 60° and must
always be set to the same angle value "α" as
angle scale 6. Loosen the handle knob 9. Move
the depth indicator 4 on the left side of setting
scale 2 (marked "cutter head Ø 150 x 115") to
the desired angle value "α" (the upper edge is
the reading line) and the tighten the handle knob
again.
Set the cutter depth to 0:
Unscrew the wing screw 10 (fig. 5). Turn the
handle 1 until the depth indicator 4 on the depth
scale 5 is at zero. Tighten the wing screw 10
(fig. 5).
The corner of the cutter of the
pivoted cutter head must be
positioned at the same level as the
base panel support.
Set the mark indicator:
The mark indicator 16 (fig. 3) shows the position
of the corner of the blade at the horizontal level.
It must therefore always be set to the same
angle value "α" as the angle scale 6 (fig. 5).
Loosen the knurled knob 17 (fig. 3). Set the
mark indicator 16 with the outer right edge over
the mark scale 15 in the area of the marking
"Set cutter head Ø 150 x 115» to angle value
'α'". Tighten the knurled knob 17.

-22-
The angle scale 6 (fig. 5), depth
indicator 4 and mark indicator 16
(fig. 3) must always be set to the
same value "α".
Parallel stop:
The parallel stop 18 (fig. 3) can be set after
loosening the wing screws 19, and it can be
used on the left or right side.
Set the machine to the mark:
Open the moving protective hood by pressing
the lever 23 (fig. 3) and set the machine onto
the wood in such a way that the end guard 37
(fig. 6) swivels back. The bird's mouth angle,
depth indicator (cutter depth 0 mm) and mark
indicator must be set in advance. With respect
to the space available, align the guide rails 34
(fig. 6) parallel left or right with spacing to the
mark A - B (fig. 4) and fasten.
Spacing between the mark and rail approx.:
to the right 10 cm (3 15/16 in.)/30°
15 cm(5 15/16 in.)/45°
20 cm (7 7/8 in.)/60°
to the left 32 cm (12 9/16 in.)/30°
30 cm (11 3/16 in.)/45°
27 cm (10 5/8 in.)/60°
Tighten adapter 33 (fig. 6) on the parallel stop 18. Set
the machine with the adapter on the guide rail and
align it to the mark indicator on mark A - B (fig. 4) by
moving it to the side in the parallel stop guides.
Tighten the wing screws 19 (fig. 3). Check the mark
on the rear mark scale 7 (fig. 5).
5.3.3 Cutting bird's mouth
Unscrew the wing screw 10 (fig. 5). Remove the
machine from the guide rail. Set cutter depth "T"
(fig. 4) by turning the handle 1 (fig. 5) to the
desired dimension in accordance with depth
scale 5.
Tighten the wing screw 10 (fig. 5) again. Set the
machine with the adapter on the guide rail so
that the cutter head with the protective hood is
exposed. Switch on the machine. Open the
moving protective hood by pressing the lever 23
(fig. 3) and cut with a uniform feed rate. The
ejected chips can be deflected by setting the
chip deflector 24. Guide the machine using both
handles 11 and 21.
When done using the machine
ensure that the moving protective
hood is closed again.
5.3.4 Milling dimensions
Cutter
head
Ø 150 x 115 (5 29/32 x 4 17/32 in.) Ø 236
x 50 (9
29/100
x 1
97/100
in.)
Ø 190
x 80
(7
31/64
x 3
5/32
in.)
∢
"α°"
0 15 30 45 60 0 0
Depth
"D"
(mm)
0 – 27
(1
1/16)
0 -
29.7
(1
11/64)
0 –
57.5
(2
17/64)
0 –
77.9
(3
1/8)
0 – 75
(2
61/64)
0 – 70
(2 3/8)
0 - 47
(1
27/32)
Width
"W"
(mm)
115 (4
17/32)
80 (1
9/16)
X
(mm)
115 (4
17/32)
115 (4
17/32)
110 (4
13/32)
86.6
(3
13/32)
Y
(mm)
30.8
(1
7/32)
66.4
(2
5/8)
110 (4
13/32)
150 (5
29/32)
5.4 Cutting oblates, grooves and cones
Set angle scale 6 (fig. 5) and mark indicator 16
(fig. 3) to 0. Depending on the cutter head user,
set the depth indicator 4 (fig. 5) to the left or
right half of the setting scale 2 (with a cutter
head of Ø 236 or 190 mm to the corresponding
markings on the right, with a cutter head of Ø
150 mm to the left). The cutter width, which at
first comprises the width of cutter head, can be
increased by moving the parallel stop laterally
18 (fig. 3).

-23-
6 Service and maintenance
Danger
Pull the power plug during all
service work.
MAFELL machines are designed to be low in
maintenance.
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.
Only use our special grease, order No. 049040 (1 kg
tin) for all greasing points.
6.1 Machine
The machine must be regularly cleaned off deposited
dust. The ventilation openings on the motor should be
cleaned with a vacuum cleaner.
The free movement of the moving protective hood
must be ensured. If it does not close by itself after it is
opened, the machine must be delivered to an
authorised MAFELL customer service workshop.
6.2 Tools
The cutter heads used on the machine should be
regularly deresinified, as clean tools improve improve
the cutting quality.
Deresinify them by placing them in petroleum or a
commercially available deresinification agent for 24
hours.
Aluminium tools may only be
deresinified with solvents which do
not corrode the aluminium.
Promptly replace damaged clamping screws and
cutting elements.
The design must not be modified with progressive
tools during servicing.
6.3 Storage
If the machine is not used for a longer period of time,
it has to be carefully cleaned. Spray bright metal parts
with a rust inhibitor.
Store the machine only in dry rooms and protect it
from the effects of weather.
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,
contact your dealer or the MAFELL customer service.
Defect Cause Elimination
No mains voltage Check power supply
Mains fuse defective Replace fuse
Machine cannot be switched on
Carbon brushes worn Take the machine to a MAFELL
customer service shop
Mains failure Check mains back-up fusesMachine switches off
automatically during idling or
stops during cutting Machine overloaded Reduce feed speed

-24-
8 Special accessories
-Guide rail length 3 m (2 parts with connector) Order No. 037037
-Guide rail length 3 m (1 part) Order No. 200672
-Guide rail extension length 1.5 m Order No. 036553
-Adapter pair for parallel stop Order No. 037195
-Complete bird's mouth cutter head Ø 150 x 60 mm Order No. 091415
-Complete bird's mouth cutter head Ø 190 x 80 mm Order No. 091417
-Complete flattening head Ø 236 x 50 mm Order No. 203659
9 Exploded drawing and spare parts list
The corresponding information in respect of spare parts can be found on our homepage: www.mafell.com