mafell DD40P Duo Dowel Jointer Instruction Manual
- June 12, 2024
- mafell
Table of Contents
- mafell DD40P Duo Dowel Jointer
- Product Information
- Technical Data
- Scope of Supply
- Safety Devices
- Safety Instructions
- Setting / Adjustment
- Operation
- Service and maintenance
- Troubleshooting
- Optional accessories
- Exploded drawing and spare parts list
- Read User Manual Online (PDF format)
- Download This Manual (PDF format)
mafell DD40P Duo Dowel Jointer
Product Information
Signs and symbols
The user manual contains various signs and symbols that provide important
information and instructions regarding the product.
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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.
Machine Identification
The product is identified as DD40G / DD40P Duo Dowel Jointer.
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Protection class II
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CE symbol to document compliance with the basic safety and health requirements according to Appendix I of the Machinery Directive.
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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.
Technical Data
The technical specifications of the product are as follows:
- Model: DD40G / DD40P
- Product Type: Duo Dowel Jointer
- Manual Version: 077039.0317/k
2.3 Technical data|
---|---
| DD40P| DD40G
Universal motor, radio and TV| 230 V~, 50 Hz or 110 V~, 50| 230 V~, 50 Hz or
110 V~, 50
interference suppressed| Hz| Hz
Power input (nominal load)| 1000 W| 700 W
Current at nominal load| 4,3 A (230 V) or 9,1 A (110 V)| 3,0 A (230 V) or 6,4
A (110 V)
Drill clearance| 32 mm (1 1/4 in.)| 32 mm (1 1/4 in.)
Drilling depth| 0 – 40 mm (0 – 1 9/16 in.)| 0 – 37 mm (0- 17/16 in.)
Swivel range| 0 – 90°| 0 – 90°
Tool diameter maximum| 16 mm (5/8 in.)| 12 mm (15/32 in.)
Tool diameter minimum| 6 mm (15/64 in.)| 3 mm (1/8 in.)
Tool receiving bore| 8 mm (5/16 in.)| 8 mm (5/16 in.)
Tool idling speed| 13500 rpm| 18500 rpm
Hose connector diameter| 35 mm (1 3/8 in.)| 35 mm (1 3/8 in.)
Weight without mains cable| 2,8 kg| 2.8 kg (6.2 lbs)
Dimensions (W x L x H)| 130 x 300 x 185 mm (5 1/8 x
11 13/16 x 7 1/4 in.)
| 130 x 300 x 185 mm (5 1/8 x
11 13/16 x 7 1/4 in.)
Noise Emission Specifications
The product meets specific noise emission specifications to ensure safe usage.
Vibration Specifications
The product meets specific vibration specifications to ensure comfortable
and efficient usage.
Scope of Supply
The product includes the following items:
- Duo Dowel Jointer
- Instruction Manual
- Safety Instructions
- Other necessary accessories
Safety Devices
The product is equipped with safety devices to ensure user safety during
operation.
The machine is equipped with the following safety devices:
- Protection against contact with the bits
- Large bearing faces of limit stops
- Handles and handle supports
- Hose connector
Use according to intended purpose
The DuoDübler is exclusively intended for drilling of solid wood and panel
materials such as chipboard, scoreboard and Mdf-boards, using the drill bits
permitted, with diameters between 3 mm and 12 mm (1/8 and 15/32 in.) (DD40G)
and from 6 mm to 16 mm (15/64 and 5/8 in.) (DD40P).
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.
Residual risks
- Touching the drill bits when fitted in or when outside the base plate.
- Touching the drill bits on the workpiece rear when drilling.
- Breakage of the drills and risk of the drill bits 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 harmful wood dusts during longer operation without extraction.
Safety Instructions
Read and follow all safety instructions provided in the user manual to prevent electric shock, fire, and serious injuries.
General instructions:
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Children and adolescents must not operate this machine. This rule does not apply to young persons receiving training and being supervised by an expert.
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Never work without the protection devices prescribed for the respective operating sequence and do not make any changes to the machine that could impair safety.
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When operating the machine outdoors, use of an An earth-leakage circuit breaker is recommended.
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Damaged cables or plugs must be immediately replaced.
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Avoid sharp bends in the cable. Especially when transporting and storing the machine, do not wind the cable around the machine.
Do not use: -
Damaged drill bits and drill bits that have changed their form.
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Blunt drill bits as they impose an excessive load on the motor.
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Drill bits that are not suitable for the drill’s idling speed.
Instructions on the use of personal protective equipment: -
Always wear ear protectors during work.
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Always where a dust mark during work.
Instructions on operation: -
Do not reach with your hands into the drilling area and do not touch the drill bits. With your other hand, support the supplementary handle or the motor casing.
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Do not reach under the workpiece.
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Never support the workpiece in your hand or over your leg. Secure the workpiece against sturdy support.
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Only hold the device by its isolated handle surfaces when carrying out work during which the cutting tool could hit hidden power cables or its own connection cable.
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Before starting to drill, tighten the drilling depth and cutting angle adjustments.
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Examine the workpiece for foreign objects. Never attempt to drill into nails or other metal objects.
Instructions on service and maintenance: -
Regularly cleaning the machine, especially the adjusting devices and guides, constitutes an important safety factor.
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Only original MAFELL spare parts and accessories may be used. Otherwise, the manufacturer will not accept any warranty claims and cannot be held liable.
Setting / Adjustment
Follow the instructions below for setting up and adjusting the product:
Mains connection
prior to commissioning make sure that the mains voltage complies with the
operating voltage stated on the machine’s rating plate.
Chip extraction
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 inside diameter of hose connector 1 (Fig. 1) is 35 mm (1 3/8 in.).
Selection of tools
Use the dowel drill bits listed in chapter 8 “Special Accessories”.
These carbide-tipped drills were developed specially for the DD40G/P and are
suitable for all types of wood.
Tool change
The basic requirement for correct drilling are well-ground drill bits.
Proceed as follows for the tool change:
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Turn the tool holding fixture 2 (Fig. 2) such that the screws 3 are on top.
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Unfasten the screws with the Allen key.
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Pull off the drill bits 4 to the front.
Push the new drill bits into the tool holding fixture up to the limit stop. Align the plain surface of the drill bits with the screw holes. -
Tighten the screws against the plain surfaces.
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Check the drill bits’ seat.
After the tool change, you have to readjust the zero setting for the drill depth. -
Unfasten the wing nut 11 (Fig. 3)
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Completely swing open the tilting stop 9.
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Tighten the wing nut 11.
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Place the machine with the swung open limit stop onto a flat surface.
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Push the motor casing 5 forward until the tip of the drill bears on this surface.
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Unfasten the wing screw 6.
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Push the depth stop 7 up to the limit stop to the top and tighten the wing screw.
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Push indicator 8 to zero.
Pivot adjustment
The tilting stop 9 (Fig. 3) can be continuously adjusted in the range from 0° to 90°. Three latching positions facilitate a fast setting of the angles 22.5°, 45° and 67.5°. -
Unfasten the wing screw 11.
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Tilt the tilting stop to the desired angle.
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Retighten the wing nut.
Drill depth adjustment
The drill depth can be continuously adjusted in a range between 0 – 37 mm (0 – 1 7/16in.) on the DD40G or 0 – 40 mm (0 – 1 9/16 in.) on the DD40P. -
Unfasten the wing nut 6 (Fig. 3)
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Push the depth stop 7 to the desired value.
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Retighten the wing nut.
Adjusting the drilling clearance
The edge clerance is continuously variable between 7 and 40 mm (9/32 and 1
9/16 in.).
- Unfasten the wing nut 16 (Fig. 4)
- Push the tilting stop 9 (Fig. 3) to the desired scale value.
- Retighten the wing nut.
With the rotating revolver limit stop 17 you can select five firmly preset edge clearances:
6.5 mm, 8 mm, 9.5 mm, 11 mm, 12.5 mm (1/4 in., 5/16 in., 3/8 in., 7/16 in., 1/2 in.)
Operation
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”.
Switching on and off
- Switching on: Push switch 23 (Fig. 5) forward until it engages.
- Switching off: Push onto the rear end of the switch. The switch jumps into off position.
Drilling according to tracing
The tilting stop 9 (Fig. 3) has three reference markings. The reference
markings on the left and right each correspond to the centre of the drill.
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Clamp the workpiece or prevent it from moving by using the anti-slip mats supplied.
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Position the machine on the workpiece and align the machine by means of the reference markings.
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With your free hand, press the tilting stop against the workpiece.
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Switch on the machine (see chapter 5.2) and push the motor casing forward up to the limit stop.
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Pull back the motor casing and switch off the machine.
Drilling with stop pin
The base plate 22 (Fig. 5) is equipped with two resilient stop pins. They are used to place the drill holes at a fixed distance to the outer edge of the workpiece. The machine stop can be positioned at the left or right. -
Clamp the workpiece or prevent it from moving by using the anti-slip mats supplied.
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Position the machine on the workpiece. At the same time you push in a stop pin 20 and allow the other stop pin to butt at the outer edge of the workpiece.
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With your free hand, press the tilting stop against the workpiece.
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Switch on the machine (see chapter 5.2) and push the motor casing forward up to the limit stop.
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Pull back the motor casing and switch off the machine.
Service and maintenance
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.
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.
Troubleshooting
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 |
Mains fuse defective | Replace fuse | |
Carbon brushes worn | Take the machine to a MAFELL customer service shop | |
Machine stops while drilling is in process | Mains failure | Check mains back-up |
fuses
Burn marks on the drill holes| Blunt drill bit| Regrind drill bit or replace
Chip ejection blocked| Wood is too damp|
Extended drilling without extraction| Connect to an external exhaustion,
e.g. portable dust extractor
Optional accessories
- Dowel drill bit – HS-TiN Ø 3 mm (1/8 in.) Order No. 090 083
- Dowel drill bit – HM Ø 5 mm (13/64 in.) Order No. 090 089
- Dowel drill bit – HM Ø 6 mm (15/64 in.) Order No. 090 096
- Dowel drill bit – HM Ø 6.1 mm (1/4 in.) Order No. 090 120
- Dowel drill bit – HM Ø 7 mm (9/32 in.) Order No. 090 121
- Dowel drill bit – HM Ø 8 mm (5/16 in.) Order No. 090 097
- Dowel drill bit – HM Ø 8.1 mm (5/16 in.) Order No. 090 122
- Dowel drill bit – HM Ø 8.2 mm (21/64 in.) Order No. 090 123
- Dowel drill bit – HM Ø 10 mm (25/64 in.) Order No. 090 098
- Dowel drill bit – HM Ø 10.1 mm (25/64 in.) Order No. 090 124
- Dowel drill bit – HM Ø 10.2 mm (13/32 in.) Order No. 090 125
- Dowel drill bit – HM Ø 12 mm (15/32 in.) Order No. 090 099
- Dowel drill bit – HM Ø 12.1 mm (15/32 in.) Order No. 090 126
- Dowel drill bit – HM Ø 12.2 mm (31/64 in.) Order No. 090 127
- Dowel drill bit – HM Ø 14 mm (35/64 in.) (only for DD40P) Order No. 090 128
- Dowel drill bit – HM Ø 15 mm (19/32 in.) (only for DD40P) Order No. 090 129
- Dowel drill bit – HM Ø 16 mm (5/8 in.) (only for DD40P) Order No. 090 085
- Dowel drill bit – HM Ø 16.2 mm (41/64 in.) (only for DD40P) Order No. 090 130
- dowel gauge with clamping device Order No. 203 980
- Dowel drilling template extension 1600 cpl., length 1600 mm (63 in.) Order No. 203 434
- Adaptor for dowel template extension Order No. 203 437
- MAFELL special dowels Ø 6×30 mm (1/4 x 1 3/16 in.), 6 x 350 pcs. Order No. 802 000
- MAFELL special dowels Ø 8×30 mm (5/16 x 1 3/16 in.), 6 x 200 pcs. Order No. 802 010
- MAFELL special dowels Ø 8×40 mm (5/16 x 1 9/16 in.), 6 x 120 pcs. Order No. 802 011
- MAFELL special dowels Ø 10×40 mm (3/8 x 1 9/16 in.), 6 x 100 pcs. Order No. 802 020
- MAFELL special dowels Ø 10×60 mm (3/8 x 2 3/8 in.), 6 x 50 pcs. Order No. 802 021
- MAFELL special dowels Ø 12×60 mm (1/2 x 2 3/8 in.), 6 x 40 pcs. Order No. 802 030
- MAFELL special dowels Ø 16×75 mm (63/100 x 2 19/20 in.), 6 x 30 pcs. Order No. 802 040
- Dowel nozzle ø 8 mm (5/16 in.) Order No. 095 060
- Bottle of glue Order No. 095 059
- Anti-slip mat wrapped, 2 pcs. Order No. 095 063
- Allen key with handle Order No. 093 282
Exploded drawing and spare parts list
The corresponding information in respect of spare parts can be found on our homepage: www.mafell.com