Mafell KFU 1000 E Quick guide

KFU 1000 E
070334.0723/l
Fugenfräse Originalbetriebsanleitung 5
Grooving Machine Translation of the original operating instructions 12
Rainureuse Traduction de la notice d'emploi originale 19
Fresa de junta Traducción del manual de instrucciones original 26
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.
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.

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English
Table of Contents
1 Signs and symbols ......................................................................................................... 13
2 Product information ........................................................................................................ 13
2.1 Manufacturer´s data ....................................................................................................... 13
2.2 Machine identification ..................................................................................................... 13
2.3 Technical data ................................................................................................................ 14
2.4 Emissions ....................................................................................................................... 14
2.5 Scope of supply .............................................................................................................. 14
2.6 Use according to intended purpose ................................................................................ 15
2.7 Residual risks ................................................................................................................. 15
3 Safety instructions .......................................................................................................... 15
4 Setting / Adjustment ....................................................................................................... 16
4.1 Mains connection ........................................................................................................... 16
4.2 Mounting the chip bag .................................................................................................... 16
4.3 Change of cutting blade ................................................................................................. 16
5 Operation ........................................................................................................................ 17
5.1 Switching on and off ....................................................................................................... 17
5.2 Adjusting cutting speed .................................................................................................. 17
5.3 Cutting depth adjustment ............................................................................................... 17
5.4 Work instructions ............................................................................................................ 17
6 Maintenance................................................................................................................... 17
7 Troubleshooting .............................................................................................................. 18
8 Special accessories ........................................................................................................ 18
9 Exploded drawing and spare parts list ........................................................................... 18

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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
for machines with product no. 951101, 951120 or 951122
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
Operating voltage 230 V AC
110 V AC
Mains frequency 50 Hz
Input power continuous operation 900 W
Cutting depth 0 - 4,5 mm (0 – 11/64 in.)
Cutting blade diameter 120 mm (4 23/32. in.)
Cutting blade bore 20 mm (1 ¼ in.)
Cutting blade speed 8000 - 13000 rpm
Cutting speed 50 – 82 m/s (164 – 279 ft/sec.)
Operating weight 3,8 kg (8.3 lbs)
Dimensions (W x L x H) 206 x 218 x 216 mm
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 power level Workplace-related emission value
Leerlauf 96 dB (A) 82 dB (A)
The stated values do not take any series variance into account and are not suitable for determining the evaluation
level according to German UVV «noise» regulations since this varies depending on the operating time, the
machining operation concerned and environmental factors. The evaluation level can consequently be determined
only in the individual instance on the premises of the machine user.
2.4.2 Vibration specifications
The typical hand-arm vibration is less than 2.5 m/s2.
2.5 Scope of supply
Grooving machine KFU 1000 E complete with:
1 TCT groove-cutting blade Ø 120 x 3.6 x 20 mm (423/32 x 1/8 in. x 20 mm), 12 teeth
1 bow for chip bag
1 chip bag
1 chip bag holder
1 service tool
1 carrying case with tray
1 operating manual
1 folder “Safety Instructions”

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2.6 Use according to intended purpose
The MAFELL grooving machine KFU 1000 E is
intended exclusively for cutting grooves for plastic
welding material into floor covering materials which will
melt when being heated (PVC and similar material).
The diameter of the groove-cutting blades used must
be 120 mm (4 23/32 in.).
Any other use beyond this scope is considered as
failing to comply with the intended purpose.
The manufacturer is not liable for any damage caused
as a result of this; the risk is borne solely by the user.
Use according to intended purpose also includes
compliance with the operating, maintenance and repair
conditions specified by MAFELL, and adherence to the
safety instructions contained in the operating manual.
The grooving machine KFU 1000 E must be operated,
tooled and maintained only by persons more than 18
years old, familiar with the machine and instructed as
to the risks.
Repair work must be carried out by authorized
MAFELL dealers or a MAFELL customer service
station.
The relevant accident prevention regulations and other
generally recognized industrial, medical and technical
safety rules must be complied with.
Unauthorized modifications to the machine preclude
the liability of the manufacturer for any resultant
damage.
2.7 Residual risks
Even when used according to the intended purpose
and in compliance with all the relevant safety
regulations, the design of the machine prescribed by
its function gives rise to potential residual risks, for
instance from the following sources:
- Touching the groove-cutting blade in the vicinity of
the cutting blade aperture at the cutting blade guard
when the machine is running.
- Touching the rotating cylinder-head screw from the
side.
- Machine kicks back if the cutting depth set of the
groove-cutting blade is too large and if the blade is
touching the floor pavement.
- Breakage of the groove-cutting blade and risk of the
groove-cutting blade or pieces of the groove-cutting
blade 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 dust: a health hazard when working for
long periods on enclosed premises without
adequate ventilation.
3 Safety instructions
Danger
If used incorrectly, grooving
machines can be dangerous. For
this reason, aways comply with the
safety instructions summarized in
this chapter, the accident
prevention regulations of the
relevant liability insurance
association or equivalent, and the
safety regulations applicable in the
country concerned!
General instructions:
- Never work without the protective equipment
prescribed for the relevant operation and do not
make any modifications to the machine that could
undermine 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.
- Prior to all work, make sure that the safety and
operating equipment is securely attached and
undamaged. Damaged protective equipment and
parts must be repaired correctly or replaced.
- Always be aware of environmental influences. Do
not allow the machine to be exposed to the rain and
do not use the machine in a damp or wet
environment, or in the vicinity of inflammable liquids
or gases.
- When operating the machine outdoors, use of an
earth-leakage circuit-breaker is recommended.
- Do not carry the machine by the cable and do not
remove the mains plug from the socket by pulling on
the cable.
- Protect the cable against oil and high temperatures
and do not pull it over any sharp edges.

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- Cutting blade cover should only be removed for
changing blades.
- Damaged cables or plugs must be renewed
immediately.
- Only use cutting blades with the technical data
stated in this manual.
- Well sharpened cutting blades should be usedonly.
- Store the machine in the dry under lock and key and
out of reach of children.
Do not use:
- Cracked and misshapen cutting blades.
- Blunt cutting blades which impose an excessive
load on the motor.
Instructions as to the use of personal safety
equipment
- Always wear close-fitting industrial clothing and
remove rings, bracelets and watches.
- The sound pressure level at the workplace generally
exceeds 85 dB (A). Users should therefore wear ear
protectors.
Instructions as to operation
- Provide an uncluttered, anti-slip location with
adequate illumination.
- Before cutting blade changes and eliminating
malfunctions pull out the mains plug.
- Machine must be switched off before being
connected to the mains.
- Hold the machine firmly even before switching on.
- Before switching on, make sure that the cutting
blade is tightly secured and that the Allen key has
been removed.
- Do not begin cutting until the cutting blade has
reached full speed.
- Examine the floor covering material for foreign
objects. Never attempt to cut nails or other metal
objects.
- When cutting, always lead the cable away from the
machine to the rear.
- Always keep your hands well away from the chip
nozzle or do not press the cutting blade guard
(rocker) while the machine is running (risk of injury!).
- Steady feeding during cutting increases the life of
the cutting blade and the machine. Never cut
backward!
Instructions as to service and maintenance
- Any work on the electric components of the machine
must be carried out only by a qualified electrician.
- Regular cleaning of the machine, especially of the
adjusting devices, the cutting blade guard (rocker),
the chip nozzle as well as the front guide roller and
the rear guide roller, is an important safety factor.
Before beginning this task, pull out the mains plug.
- Only original MAFELL spare parts and accessories
must be used. Otherwise the manufacturer does not
offer any warranty and does not accept any liability.
4 Setting / Adjustment
4.1 Mains connection
The gooving machine KFU 1000 E has Class II
protective insulation (double-insulated).
Before starting up, make sure that the mains voltage
matches the voltage stated on the rating plate.
Machine must be switched off before being
connected to the mains.
4.2 Mounting the chip bag
Put both free end pieces of the complete chip bag into
the holes of the base plate.
4.3 Change of cutting blade
Always pull out the mains plug
before changing the cutting blade!
Do not fit cutting blades that are
cracked or otherwise damaged.
Only use cutting blades with a
diameter of 120 mm (4 23/32 in.).
Do not use cutting blades with a
bore diameter other than 20 mm.
Make sure that the cutting blade
being mounted is properly
sharpened since this is the basic
requirement for perfect joints.
Proceed as follows to change the cutting blade:
Remove cutting blade cover 19 by loosening the 4 flat-
head screws 45. Press locking pin 26 and turn the
cutting blade slowly until it catches. Loosen the
clamping flange with the Allen key (note left-hand
thread!). When inserting the new cutting blade, note
the correct direction of rotation: the teeth of the cutting
blade must point in the same direction as the arrow on

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the cutting blade cover. Then put cutting blade cover
19 on and tighten flat-head screws 45.
Make sure that all contact surfaces on the flanges and
blade are clean.
If the cutting blade and the guide rollers are not
properly aligned, the guide rollers should be adjusted.
5 Operation
5.1 Switching on and off
Do not switch on the machine if the
cutting blade is touching the floor
covering material.
Temporary operation
Switching on: Press switch 92/1.
Switching off: Release the switch.
Continuous operation
Switching on: Press switch 92/1 first and then press
locking button 92/2. The motor runs wiuthout keeping
the switch pressed.
Switching off: Press switch 92/1 until locking button
92/2 trips, then release the switch.
5.2 Adjusting cutting speed
This grooving machine has an electronic speed
control. The cutting speed can be adjusted
continuously between 8000 and 13000 rpm. Thus, the
cutting speed can be adapted to the material used.
The built-in electronics ensure a jerk-free acceleration
when switching on and control the speed according to
the value set.
The required speed can be set by means of the setting
wheel on the motor cover.
5.3 Cutting depth adjustment
The cutting depth is adjusted by turning knurledhead
screw 28. Turning clockwise reduces,
counterclockwise increases the cutting depth. Turning
the knurled-head screw down completely reduces the
cutting depth to 0 mm. When cutting grooves, make
sure that the cutting blade will not cut into the concrete
or flooring plaster as this may damage the carbide-
tipped teeth.
When the cutting depth has been set, it is
recommended to cut a trial groove into a piece of waste
material.
5.4 Work instructions
Place the grooving machine down on the floor covering
in such a way that the two guide rollers are placed on
the slit of the joint between two sheets of floor
coverings. The front guide roller 31 in front of the
cutting blade has a thin knife-like profile to follow the
slit of the joint. Rear guide roller 32 has the same
profile as the teeth of the cutting blade so that it
completely fills the groove to be cut. Hold the machine
firmly, switch on, lower the machine into working
position by pressing it down smoothly and start cutting.
After a few cm / inches rear guide roller 32 will be fully
inserted into the groove providing reliable guidance in
conjunction with the front guide roller.
When cutting, make sure that the machine is
advanced evenly and firmly, to prevent that chips
are heated up, melted and glued together.
Beginning and end of the groove must be completed
with a hand grooving tool.
Attention: The thin profile of the front guide roller is
rather delicate and may be damaged when hitting
concrete or metal, which in turn may reduce its guiding
capacity.
6 Maintenance
Danger
Prior to doing any maintenance
work always pull out the mains
plug!
The grooving machine KFU 1000 E is designedwith a
low maintenace requirement. The ballbearing are
greased for life.
The machine must be regularly cleaned of dust, at the
same time blowing out of the motor ventilation
apertures.
After a prolonged period of operation, users are
recommended to have the machine checked by an
authorized MAFELL customer service shop.

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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
Machine cannot be switched on No mains voltage Check power supply
Carbon brushes worn Take the machine to a MAFELL
customer service shop
Machine stops while cutting is in
process
Mains failure Check mains back-up fuses
8 Special accessories
The following optional accessories are available for the grooving machine KFU 1000 E:
1. TCT cutting blades:
- Groove-cutting blade Ø 120 x 3,6 x 20 mm, 12 teeth Ref. No. 091794
- Groove-cutting blade Ø 120 x 4,2 x 20 mm, 12 teeth Ref. No. 091795
2. Rear guide roller cpl., R 1,5 Ref. No. 202274
3. Hand grooving tool, semi-circular with 5 replacement knives Ref. No. 091460
- Replacement knives for hand grooving tool, semi-circular Ref. No. 091467
4. Push handle long Ref. No. 202545
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 ou de la fabrication, à l'exclusion des
pièces de consommation et d'usure. La machine ou l’appareil doit être pour cela expédié 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.
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.
MAFELL AG
Beffendorfer Straße 4, D-78727 Oberndorf / Neckar
Telefon [phone]
Fax [phone]
Internet:
www.mafell.de
E-Mail:
[email protected]