mafell PF80 Face Milling Cutter Instruction Manual

PF80
Face milling cutter
Translation of the original operating manual MAF02338/a

PF80 Face Milling Cutter

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.

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.

Product information

for machine with Art.-No. 91D401
2.1 Manufacturer´s data
MAFELL AG, Beffendorfer Straße 4, D-78727 Oberndorf / Neckar, Phone +49 (0)7423/812-0, Fax +49 (0)7423/812-218, e-mail: mafell@mafell.de
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.
2.3 Technical data
Universal motor   230 V~, 50 Hz
Input power  1050 W
Idling speed   4,200 – 10,000 min -1
Hose connector diameter  35 mm (1.37 inches)
Cutter diameter  80 mm (3.14 inches)
Weight without mains cable  3.1 kg
Dimensions (W x L x H)
160 x 350 x 155 mm (6.29 x 13.77 x 6.10 inches)
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 DIN EN ISO 3744:

The noise measurement was done without tool at idling speed.
2.4.2 Vibration specifications
The typical hand-arm vibration is less than 2.5 m/s 2 .
2.5 Scope of supply
Face milling cutter PF80 complete with:
1 milling head
1 hose connector
1 connecting cable
2 operating tools
1 carrying case
1 operating manual
1 folder “Safety instructions”
2.6 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:
– Large base plate
– Handles
– Index mechanisms
– Hose connector
– Protective screen
– Protective ring
– Electronic system with restart protection
2.7 Use according to intended purpose
The face milling cutter PF 80 is only suitable for face milling of material projections over flat surfaces made of solid wood or wood-like materials.
For this, the base plate of the machine must rest on the flat areas of the workpiece. Hand-guided processing is not permitted. (Risk of backlash)
Only use the tool included in the delivery.
Do not remove any safety devices to enable work other than that described above.
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.
2.8 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 that can lead to health consequences will always remain.
– Machine backlash.
– Touching the milling cutter below the protective screen.
– Putting down the machine while the tool is coasting to a standstill and a resulting unexpected movement of the machine or of an entrained object.
– Breakage and hurling out of the tool or parts of the tool.
– Hearing impairment when working for long periods without ear protectors.
– Emission of hazardous wood dusts when operating the machine for longer periods of time without extraction.

Safety instructions

Danger
Always observe the following safety instructions and the safety regulations applicable in the respective country of use!
General instructions:
– 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.
– Children and adolescents must not operate this machine. This rule does not apply to young persons receiving training and being supervised by an expert.
– When operating the machine outdoors, use of an earth-leakage circuit-breaker is recommended. Use in wet conditions or in rain is prohibited.
– Secure the workpiece against shifting and always operate the machine with both hands.
– Do not put down the machine before the tool has coasted to a standstill.
– 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. Especially when transporting and storing the machine, do not wind the cable around the machine.
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:
– Keep your hands away from the cutting range and the tool. With your other hand, support the supplementary handle or the motor casing.
– Never support the workpiece in your hand or over your leg. Secure the workpiece against a sturdy support, e.g. by means of clamps.
– Only hold the power tool by the isolated handles, as the milling cutter could encounter and cut into its own connecting cable.
– Never use damaged or incorrect tool washers or screws.
– Hold the machine with both hands and bring your arms into a position where you are able to resist the backlash forces.
– Examine the workpiece for foreign objects. Do not saw or mill into steel parts.
– Always mill in counter direction.
– Before starting up, check the tight seat of the milling cutter and its correct running.
– Only use milling cutters approved for manual feed.
Only use the tool included in the delivery or a corresponding spare part.
– Never reach underneath the protective screen. Pull out the mains plug before cleaning the protective screen.
– Always lead the connecting cable away from the machine to the rear while milling.
– Before tool changes, making adjustments and eliminating malfunctions (including the removal of trapped splinters), pull out the mains plug.
– Before switching on, make sure that the milling cutter is tightly secured.
– Use clamps or another practical way to secure and support the workpiece to a stable platform.
– Only switch on the machine once its rests on the flat surface to be processed. After processing, switch off the machine and only lift it off the workpiece once the tool has coasted to a standstill.
– Only begin milling the workpiece when the milling cutter has achieved its full speed.
– Examine the workpiece for foreign objects. Do not mill into metal parts, e.g. nails.
– Only start working if the base plate can be securely rested on the workpiece.
– Hand-guided milling is not permitted.
– The wood dust arising during milling impairs the necessary view and is partly injurious to health. If the machine is used for longer periods, it must therefore be connected to a chip extractor if the work is not carried out outdoors or in a sufficiently ventilated room.
Instructions on service and maintenance:
– Regularly cleaning the machine, especially the adjusting devices and guides, constitutes 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.

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 Chip extraction
Danger
Substances that are harmful to health must be taken up with an Msuction device.
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 is 35 mm ( 1 3/8 in.).
4.3 Changing the cutter
Danger
It is imperative to pull the mains plug before replacing the milling cutter.
So as to guarantee its function, the machine is harmonised with the milling cutter included in the delivery, therefore only a corresponding spare part can be used.
– The tool holder is locked with pushbutton 109.
– Release cylinder head screw 26 by means of the hexagon wrench key.
– Replace the milling cutter 3 and tighten it again (10 Nm). Pay attention to the cylinder pins and ensure that there are no chips on the clamping surfaces.
Deresinification is carried out by soaking the cutters for 24 hours in paraffin or commercially available resin remover.
4.4 Changing the indexable cutting insert
Danger
Pull the power plug during all service work.
Danger
Indexable cutting inserts are cuttingtools and have sharp corners and sharp edges. Handle these indexable cutting inserts with care to prevent injuries and damage to the inserts.
The milling head is equipped with 4 HM carbide indexable cutting inserts. If the blades are becoming blunt, you can turn the indexable cutting insert three times. After that, new original indexable cutting inserts must be fitted!
Follow the procedure below:
– Unscrew the countersunk screws using the torx screw driver.
– Clean all parts and the cutter chambers of the milling head.
– Turn or replace the indexable cutting inserts.
– Fasten the indexable cutting inserts with the countersunk screws and retighten these with the torx screw driver (4 Nm).
The parts have been inserted correctly if the rear of a cutter edge is resting against the carrier body and the countersunk screw can be screwed in that far that the surface of the countersunk screw is located below or on the same level as the surface of the indexable
cutting insert. The radial blade protrusion of max. 1.1 mm is thus guaranteed.

Operation

5.1 General
– Personnel entrusted to work with the machine must be made aware of these operating instructions, calling particular attention to the chapter “Safety instructions”.
– Ensure that the cutter is fastened correctly.
5.2 Switching on and off

• Switching on: Push control button 56 forward until it engages.
• Switching off:Lightly press control button 56 in the rear area until the catch is released, then let go of the control button.

The machine is equipped with a restart protection. If the control button 56 accidentally remains in the “On” position and the machine is connected via the mains cable it will not start to run. To start the machine, it must first be switched off and then on again.

5.3 Work instructions
– Hold the face milling cutter with both hands at handle 13 and motor casing 34.
– Place the base plate of the machine securely on the flat area of the workpiece.
– Switch on the machine.
– Switch off the machine when you remove one of your hands from the machine or lift the machine. Observe the time it takes the machine to coast to a standstill.
Danger
Switch off the motor before putting the machine aside.

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.
6.2 Cutter
The milling cutters used on the machine must be freed from resin regularly as clean tools improve the cutting quality.
For cleaning, only acid-free but not highly alkaline cleaning agents may be used.
Deresinification is carried out by soaking the cutters for 24 hours in paraffin or commercially available resin remover.
6.3 Storage
If the machine is out of service for a lengthy period of time, it should be thoroughly cleaned (see chapter 6.1).
Spray bright metal parts with a rust inhibitor. Only store the machine in dry rooms and protected from the effects of the weather.

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, please contact your dealer or the MAFELL customer service directly.

power supply checked by an electrician
Mains fuse defective| Have fuse replaced by an electrician
Carbon brushes worn| Take the machine to a MAFELL customer service shop
Machine switches off automatically during idling or stops during the milling process| Mains failure| Have mains-side pre-fuses checked by an electrician
Milling cutter jams as the machine is advanced| Blunt milling cutter| Switch off the machine immediately.
Remove the machine from the workpiece and replace the milling cutter
Replace the indexable cutting inserts
Burn marks on the milled surfaces| Milling cutter that is unsuitable for the operating sequence or blunt| Replace the indexable cutting inserts
Replace the milling cutter
Chip ejection blocked| Wood is too damp| Dry the wood
Extended milling without extraction| Connect machine to an external extraction system
Power failure| Restart protection| _ Switch machine off and on again

Optional accessories

Reversible scoring knives for milling head
Order No. 034907

Exploded drawing and spare parts list

The corresponding information in respect of spare parts can be found on our homepage: www.mafell.com

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 b e 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.
EC Declaration of Conformity
We herewith confirm that the machine PF 80 complies with the EU directives quoted. The standards listed were used for design and construction. Empowered person for the configuration of the technical documents: Mafell AG
**** 20061421EG
2014/30/EU
2011/651EU PF 80
Mafell AG Beffendorfer Str. 4 D – 78727 Oberndorf, den 20.10.2022
EN 62841-1, EN 62841-2-17, EN55014-1, EN 55014-2, EN 61000-3-2, EN 61000-3-3, EN 12100, EN 847-1
Art.-Nr. 91D401

MAFELL AG
Beffendorfer Straße 4, D-78727 Oberndorf / Neckar
Telefon +49 (0)7423/812-0
Fax +49 (0)7423/812-218
Internet: www.mafell.de
E-Mail: mafell@mafell.de

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