Mafell DDF 40 Assembly instructions

DDF40
170756.0122/a
IMPORTANT
Read Before Using
IMPORTANT
Lire avant usage
IMPORTANTE
Leer antes de usar
Operating/Safety Instructions
Consignes d’utilisation/de sécurité
Instrucciones de funcionamiento y seguridad
For English Version
See page 2
Version française
Voir page 29
Versión en español
Ver la página 57

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English
Table of contents
1Signs and symbols ........................................................................................................... 3
1.1 Identification of the device................................................................................................5
2Product specifications ......................................................................................................6
2.1 Technical data .................................................................................................................. 6
2.2 Scope of delivery.............................................................................................................. 7
2.3 Adjustment elements........................................................................................................8
3General safety .................................................................................................................. 9
3.1 Intended use..................................................................................................................... 9
3.2 Foreseeable misuse .........................................................................................................9
3.3 Safety instructions .......................................................................................................... 10
3.4 Specific safety rules .......................................................................................................11
3.5 Safety devices ................................................................................................................12
3.6 Residual risks ................................................................................................................. 13
4Setup / adjustment .........................................................................................................13
4.1 Mains connection ...........................................................................................................13
4.2 Routing of the connecting cable ..................................................................................... 13
4.3 Chip extraction ............................................................................................................... 14
4.4 Tool change.................................................................................................................... 14
4.5 Swivel setting .................................................................................................................16
4.6 Drilling depth setting.......................................................................................................17
4.7 Height adjustment of the swiveling guide fence .............................................................18
5Operation........................................................................................................................19
5.1 Startup............................................................................................................................19
5.2 Switching on / off ............................................................................................................19
5.3 Drilling ............................................................................................................................ 20
5.4 Drilling with accessories ................................................................................................. 21
5.5 Working with special accessories................................................................................... 25
6Service and maintenance...............................................................................................27
6.1 Storage........................................................................................................................... 27
7Troubleshooting.............................................................................................................. 27
8Optional accessories ...................................................................................................... 28
9Exploded view and spare parts list................................................................................. 28

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1Signs and symbols
These operating instructions contain the following general information signs to guide you, the reader, through
the operating instructions and to provide you with important information.
Sign
Meaning
Important information
This sign highlights user tips and other useful information.
➢
Identifies an intermediate result in a sequence of actions.
✓
Identifies the final result of a sequence of actions.
Tab. 1: General signs and their meanings
Warning icons warn of dangerous points, risks and obstacles.
Icon
Meaning
Warning
This icon can be found at all locations where you can find information regarding your
safety. Non-observance can result in extremely serious injuries.
Warns of danger of electric shock.
Warns of danger caused by dust.
Warns of danger caused by drilling.
Tab. 2: Warning icons and their meanings

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Mandatory icons are intended to prevent accidents.
Icon
Meaning
Wear eye protection.
Wear dust mask.
Wear hearing protection.
Wear protective gloves.
Tab. 3: Mandatory icons and their meanings
During the operation of the power tool there are always actions to be taken where hazards can occur. These
potentially dangerous actions are preceded by warnings which must be observed.
Classification of the danger level (signal words) of warnings
Warning
Meaning and consequences of non-observance
Imminent danger that will cause serious or fatal injuries.
Potentially dangerous situation that can cause serious or
fatal injuries.
Potentially dangerous situation that can cause minor
injuries.
Tab. 4: Structure of warnings

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1.1 Identification of the device
The icons listed and explained below can be found on the rating plate or on the product.
Icon
Explanation
Icon
Explanation
V
Volt
1, 2, 3, ...
I, II, III, ...
Rotational speed setting
A
Ampere
rpm
Revolutions per minute
Hz
Hertz
ø
Tool diameter
W
Watt
~
Alternating current
kg
Kilogram (weight)
Protection class II
min
Minutes (time)
Read operating instructions
s
Seconds (time)
Protective goggles
n0
Rated speed at no load
Hearing protection
n
Rated speed at normal load
Dust mask
Danger icon pierced fingers

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2Product specifications
2.1 Technical data
Universal motor
120 V~, 60 Hz
Power consumption (normal load)
900 W
Current at normal load
8.2 A
Tool speed at no load
8000 rpm
Drill spacing
32 mm [1.26 in]
Drilling depth
0 - 40 mm [0 - 1.57 in]
Swivel range
0°–90°°
Maximum tool diameter
12.2 mm [0.48 in]
Minimum tool diameter
3 mm [0.12 in]
Tool seating bore
8 mm [0.32 in]
Hose connector diameter
29 mm [1.14 in]
Weight without power cord
2.8 kg [6.17 lbs]
Dimensions (width x length x height)
145 x 300 x 164 mm [5.71 x 11.81 x 6.46 in]

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2.2 Scope of delivery
Fig. 1: Scope of delivery
Components
A
DuoDowel DDF40
B
2 dowel drill HW 8 mm [0.31 in]
2 dowel drill HW 6 mm [0.24 in]
C
Transport box
D
2 anti-slip mats
E
Lateral guide fence set SA 320
F
Batten guide fence LA
G
Ancillary guide fence set ZAG
H
Ancillary support ZA
I
Position indicator PAZ
J
Hose connector
Additionally included:
1 Allen key with handle
1 glue bottle 250 ml (empty)
1 glue nozzle ø 8 mm [0.31 in]
200 round wooden dowels 8 x 30 mm [0.31 x 1.18 in]
350 round wooden dowels 6 x 30 mm [0.24 x 1.18 in]

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2.3 Adjustment elements
Fig. 2: Left and right adjustment elements
Adjustment elements on the machine
1
Swiveling guide fence
2
Height adjustment scale
3
Height adjustment wing screw
4
Power switch
5
Turret stop
6
Rotary button
7
Setting wheel
8
Swivel setting wing screw
9
Swivel setting scale
10
Depth stop 1
11
Depth stop 2

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3General safety
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.
3.1 Intended use
The DuoDowel is only intended to be used for drilling wood, using drill bits with a diameter of 3 - 12.2 mm [0.12
- 0.48 in] that have been approved by Mafell. In this process, connections are made between individual parts in
the workbench area.
3.2 Foreseeable misuse
The machine is not intended for any other use than the intended use listed above.
The manufacturer is not liable for any damage resulting from such other use.
To use the machine as intended, comply with the operating, maintenance and repair conditions specified by
MAFELL.
Foreseeable misuse also includes:
- Tampering with, removing and/or bypassing safety devices of any kind.
- Operating the machine without safety devices.
- Non-observance of safety and warning instructions in the operating instructions.
- Removing the safety and warning labels from the machine.
- Operating the machine by unauthorized persons.
- Failure to follow prescribed maintenance and care instructions.
- Using the machine for drilling holes in existing walls.
Never use:
- Cracked and/or deformed drill bits.
- Blunt drill bits as they impose an excessive load on the motor.
- Drill bits that are not suitable for the no-load speed of the power drill.

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3.3 Safety instructions
READ ALL INSTRUCTIONS!
Non-observance of the instructions listed below can cause electric shock, fire and/or serious injuries
.
Work area
- Children and adolescents are not allowed to operate this machine.
- When using the machine outdoors, the use of an earth leakage circuit breaker is recommended.
- Replace damaged cables or plugs immediately. To avoid safety hazards, only MAFELL or an authorized
MAFELL service workshop is allowed to replace parts.
- Prevent sharp kinks of the cable. Do not wrap the cable around the machine, especially when transporting
and storing the machine.
- Do not use this machine when you are tired, or under the influence of drugs, alcohol or medicaments. Be
aware of what you are doing. Stay alert and use common sense.
- Keep children and bystanders at a distance while you are operating the machine. Distractions can cause
you to lose control of the machine.
- Use eye protection, dust mask and hearing protection. Appropriate safety equipment, used
under proper conditions, will reduce the risk of injuries.
Instructions for service and maintenance:
- Cleaning the machine regularly, especially the adjustment elements and the guiding devices, is an important
safety factor.
- Ensure that only genuine MAFELL spare parts and accessories are used. Failure to do so will make
warranty claims and the liability of the manufacturer null and void.
- Prepare a periodic maintenance schedule for your machine. When you clean the machine, be careful
not to disassemble any part of the machine. Reassembling the machine bears the risk that internal
wires are routed incorrectly or pinched, or that return springs of the safety device are mounted
incorrectly. Certain cleaning agents, such as gasoline, carbon tetrachloride, ammonia, etc. can damage
plastic parts.
- Some of the dust produced by sawing, sanding, drilling and other building work contains chemicals
known to cause cancer, birth defects or other reproductive harm. Some examples of these
chemicals are:
- Lead from lead-based paints,
- Crystalline silica from bricks and cement and other masonry products,
- Arsenic and chromium from chemically treated wood.
Your risk from this hazard varies with the frequency at which you perform this type of work. To reduce your
exposure to these chemicals: Work in a well-ventilated area. Work only with approved safety equipment, such
as dust masks that are specially designed to filter out particles of microscopic size.

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3.4 Specific safety rules
Operation information:
- Keep your hands away from drilling area and drill bits.
- During the drilling process, never reach underneath the workpiece (risk of injury!).
- Never hold the workpiece in your hands or across your leg while you are drilling. Secure the workpiece on a
stable support.
- Hold the power tool by the insulated grip surfaces when you perform work that involves a risk of the tool
hitting hidden power lines or its own power cord.
- Maintain the work area in a clean and tidy state. Ensure that there are no live lines in the work area
(extension cables, own connecting cable).
- Prior to starting drilling, tighten the height and angle settings.
- Check the workpiece for foreign bodies. Do not drill into metal parts, such as nails.
- During your work routines, pay attention that you always put down the machine in a safe place when it is not
in use. This prevents injuries due to the machine falling down.
- After drilling, the motor unit must automatically move back to the home position. The drill bits are
then completely inside the protective cover. If this is not the case, switch off the machine immediately and
repair it before you use it again.
RETAIN THESE INSTRUCTIONS!

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3.5 Safety devices
Danger
Risk of injury from missing safety devices
These devices are necessary for the safe operation of the machine. They must
not be removed or rendered ineffective.
➢Check the proper functioning of the safety devices before you start
operating the machine.
➢Never use the machine with missing or ineffective safety devices.
The machine is equipped with the following safety devices:
Safety device
Type of check
Switch interlock during tool change
Functional check (actuate rotary button)
Contact protection for drill bit
Visual check for damage
Large contact surfaces of base plate and swiveling
guide fence
Visual check for damage and deformation
Handles
Visual check for damage
Switching device and brake
Functional check (braking time must not be longer
than 5 seconds)
Hose connector
Visual check for damage and obstruction
If the safety devices are damaged or not functioning properly, follow the instructions in the chapter
Troubleshooting. For other malfunctions, please contact your dealer or MAFELL Customer Service directly.

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3.6 Residual risks
Warning
Risk of injury when working with the machine
Even when the machine is used as intended and in compliance with the safety
regulations, there are still residual risks caused by the intended use, which can
have consequences for your health.
➢Observe the safety instructions and information in these instructions.
➢Always be extremely careful and cautious when you work with the machine.
The existing residual risks include:
- Touching the drill bits inside and outside the base plate.
- Touching the drill bits at the rear of the workpiece when drilling through.
- Breakage and ejection of the drill bits or parts of the drill bits.
- Ejected chips.
- Impaired hearing when working without hearing protection for long periods of time.
- Emission of harmful wood dusts during longer operation without extraction.
4Setup / adjustment
4.1 Mains connection
Prior to starting up the machine, check to ensure that the mains voltage corresponds to the operating voltage
specified on the rating plate of the machine.
4.2 Routing of the connecting cable
Warning
Electric shock when drilling into the connecting cable
The connecting cable can impair safety functions and work functions and
get into contact with the drilling tool. Drilling into the connecting cable of the
machine energizes the metal parts of the machine and causes an electric
shock. There is a risk of injury for the user.
➢When working, pay attention to the way the connecting cable is
routed.
➢Never drill into the connecting cable of your machine.

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4.3 Chip extraction
Caution
Health hazards from wood dust
The dusts produced during work can be inhaled and can cause health damage.
➢Harmful dust must be extracted with a HEPA 13 dust extractor.
➢Wear a dust mask during work.
For all work that produces a significant amount of dust, connect the machine to a suitable external extraction
device. The air velocity must be at least 20 m/s [65 ft/sec].
The outside diameter of the hose connector is 29 mm [1.14 in]. The hose connector is mounted as described in
section 5.4.6 Drilling with hose connector.
4.4 Tool change
Sharp drills are the basic prerequisite for perfect drilling.
Use the dowel drills listed in the chapter Special accessories. These carbide-tipped drill bits have been
especially developed for the machine and are suitable for all types of wood.
Use the following procedure to change the drill
bits:
1. Pull out the power plug of the machine.
2. Put down the cable where you can see it.
3. Put the disconnected machine on a flat surface.
4. Rotate the rotary button (6) to the tool change
icon ( ).
➢The power switch is blocked.
Fig. 3: Setting the rotary button to the tool change icon

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5. Push the motor unit forward until it locks into
place.
6. Turn over the machine.
Fig. 4: Pushing the motor unit forward
7. Using the Allen key, turn the tool holder (12)
that is visible in the oblong hole such that the
screws (13) are visible in the holes of the base
plate.
8. Using the Allen key, turn the screws (13)
counterclockwise to loosen them.
9. Pull off the old drill bit (14) from the front.
10. Insert the new drill bits (14) into the tool seating
bore until they hit the stop.
11. Tighten the locking screws (13) clockwise.
➢Check to ensure that the drill bits are
seated properly.
Fig. 5: Loosening and changing the drill bits
12. Set the rotary button (6) to drilling depth "1" or
"2".
➢The machine moves automatically back to
the home position.
✓Drill bits changed.
Fig. 6: Set the rotating rotary button to drilling depth "1" or
"2"
Ensure that you check the zero setting of the drilling depth after you have changed the tool.
Readjust it if necessary.

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Use the following procedure to check the zero
setting of the drilling depth:
1. Set depth stop "1" to scale depth 0 mm.
Fig. 7: Setting depth stop "1" to scale depth 0
2. Set the rotary button to drilling depth "1".
3. Push the motor unit forward.
4. Check whether drill tip or cutting edge (as
desired!) is level with the contact surface.
Fig. 8: Setting the rotary button to drilling depth "1"
5. If necessary, rotate the screw (15) at the stop
with the Allen key until the zero position is
correct.
➢Upon delivery, this is set to the drill cutting
edge!
✓Zero setting of the drilling depth checked.
Fig. 9: Adjusting the zero setting
4.5 Swivel setting
The swiveling guide fence can continuously be adjusted in the range from 0° through 90°. Three detent
positions allow quick adjustment of the angles 22.5° / 45° / 67.5°.

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Use the following procedure to adjust the
swiveling guide fence:
1. Loosen the wing screw (8) for the swivel setting.
2. Swing the swiveling guide fence (1) to the
desired direction.
➢The angle is indicated by the red pointer
on the scale (9).
3. Tighten the wing screw (8).
✓Swiveling guide fence adjusted.
Fig. 10: Adjusting the swiveling guide fence
4.6 Drilling depth setting
The drilling depth can be set continuously in a range between 0 and 40 mm [0 to 1.57 in] in 1-mm increments
[0.04 in].
Use the following procedure to adjust the drilling
depth:
1. Press and hold the button on the depth stop "2"
and move the stop to the larger depth (2 - 40
mm | 0.08 - 1.57 in).
2. Press and hold the button on the depth stop "1"
and move the stop to the smaller depth (0 - 38
mm | 0 - 1.50 in).
3. Set the rotary button (6) as required to drilling
depth "1" or "2".
✓Drilling depth adjusted.
Fig. 11: Adjusting the drilling depth

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4.7 Height adjustment of the swiveling guide fence
The height of the swiveling guide fence and thus the drilling distance to the support surface can be adjusted
continuously in a range between 6.5 and 60 mm [0.26 and 2.36 in] to the drill axis.
Use the following procedure to adjust the height
of the swiveling guide fence:
1. Loosen the wing screw (3) for the height
adjustment.
2. Using the setting wheel (7), set the required
height of the swiveling guide fence (1).
➢The height is indicated by the red pointer
on the scale (2).
3. Tighten the wing screw (3).
✓Height of the swiveling guide fence
adjusted.
Fig. 12: Adjusting the height of the swiveling guide fence
Using the rotating turret stop (5), you can select one of five fixed preselected distances:
6.5 mm
[0.26 in]
8 mm
[0.31 in]
9.5 mm
[0.37 in]
11 mm
[0.43 in]
12.5 mm
[0.49 in]
In addition, a freely adjustable distance can be
selected. To do this, use the 2.5-mm Allen key
provided to turn the screw in the turret stop.
Fig. 13: Adjusting the distance at the turret stop

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5Operation
5.1 Startup
These operating instructions must be brought to the attention of all persons entrusted with the operation of the
machine, with particular emphasis on the chapter "Safety instructions".
5.2 Switching on / off
Use the following procedure to switch on the
machine:
1. Press down the power switch (4) until it
engages.
✓The machine is switched on.
Use the following procedure to switch off the
machine:
1. Press the power switch (4).
➢The power switch jumps to the OFF
position.
✓The machine is switched off.
Fig. 14: Switching the machine ON/OFF
The power switch is blocked in the tool change position ( )!
Check the setting of the rotary button (6).

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5.3 Drilling
The base plate is equipped with two resilient stop
pins (16). They are to drill the boreholes at a fixed
distance of 15.5 mm [0.61 in] from the outer edge of
the workpiece.
There are contact surfaces (17) on the sides of the
base plate. They are used to drill the boreholes at a
fixed distance of 49 mm [1.93 in] from the outer edge
of the workpiece.
The machine can be mounted on the left and on the
right side.
Fig. 15: Base plate with stop pins and contact surfaces
There a several orientation markings on the machine.
The base plate has markings on the top, front and
bottom side:
- Contact edge of the accessory guide fences (A)
- Inside of the stop pins (B)
- Drill bit center (C)
- Machine center (D)
The markings on the left and right of the side surfaces
correspond to the drill bit center.
Fig. 16: Markings on the machine
Likewise, vertical drilling with the machine is possible
by folding the swiveling guide fence (1). The swiveling
guide fence can then be used as an additional
support.
There are three markings on the swiveling guide
fence. The center marking corresponds to the
machine center. The markings on the left and right
correspond to the corresponding drill bit center.
Ensure that the contact surfaces of machine and
workpiece are precisely aligned with each other.
Fig. 17: Preparing the machine for vertical drilling
For vertical drilling with the swiveling guide fence, Mafell recommends using the ancillary
support ZA to provide a secure support. See also chapter 5.4.4 Drilling with ancillary
support.