Mafell DD40P Duo Dowel System – Timberwolf Tools Instruction Manual

: June 5, 2024
: mafell

Mafell DD40P Duo Dowel System – Timberwolf Tools Instruction Manual

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.

Icon This symbol indicates tips for the user and other useful information.

Product information

For machines with product no. 916001, 916002, 916010, 916020, 916021, 916025, 916030, 916031, 916032, 916033, 916034, 916035, 916040, 916041, 916042, 916043, 916045

Manufacturer´s data

MAFELL AG, Beffendorfer Straße 4, D-78727 Oberndorf / Neckar, Phone +49 (0)7423/812-0, Fax +49 (0)7423/812-218

Machine identification

All details required for machine identification are available on the attached rating plate.

Icon Protection class II

CE symbol to document compliance with the basic safety and health requirements according to Appendix I of the Machinery Directive.

Dustbin icon 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.

Icon To reduce the risk of injury, please read the operating instructions.

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

Noise emission values determined according to EN 60745-1:

| Sound power level| Workplace-related emission value
---|---|---
Idling| 100 dB (A)| 89 dB (A

The noise measurement was recorded using the tool included in the standard equipment.

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.

Vibration specifications

The typical hand-arm vibration is less than 2.5 m/s2

Scope of supply

DD40G MidiMAX

Item No. 916001, 916020, 916021, 916025
2 carbide-tipped dowel drill bits ø 8 mm (5/16 in.)
1 pack of MAFELL special dowels ø 8×30 mm (5/16 x 1 3/16 in.) (approx. 200 pcs.)
1 bottle of glue
2 anti-slip mats
1 Allen key with handle
1 service tool in bracket on the machine
1 carrying case
1 operating manual
1 folder “Safety Instructions”

DD40G MaxiMAX

Item No. 916002, 916030, 916031, 916032, 916033, 916034, 916035
2 carbide-tipped dowel drill bits ø 6 mm (1/4 in.)
2 carbide-tipped dowel drill bits ø 8 mm (5/16 in.)
2 carbide-tipped dowel drill bits ø 10 mm (3/8 in.)
1 pack of MAFELL special dowels ø 6×30 mm (1/4 x 1 3/16 in.) (approx. 350 pcs.)
1 pack of MAFELL special dowels ø 8×30 mm (5/16 x 1 3/16 in.) (approx. 200 pcs.)
1 pack of MAFELL special dowels ø 10×40 (3/8 mm x 1 9/16 in.) (approx. 100 pcs.)

Further scope of delivery:

1 bottle of glue
1 dowel nozzle ø 8 mm (5/16 in.)
2 anti-slip mats
1 Allen key with handle
1 service tool in bracket on the machine
1 carrying case
1 operating manual
1 folder “Safety Instructions”

DD40P PowerMAX

Item No. 916010, 916040, 916041, 916042, 916043, 916045
2 carbide-tipped dowel drill bits ø 8 mm (5/16 in.)
2 carbide-tipped dowel drill bits ø 10 mm (25/64 in.)
2 carbide-tipped dowel drill bits ø 12 mm (15/32 in.)
1 pack of MAFELL special dowels ø 8×30 mm (5/16 x 1 3/16 in.)
1 pack of MAFELL special dowels ø 10×40 mm (3/8 x 1 9/16 in.)
1 pack of MAFELL special dowels ø 12×60 mm (1/2 x 2 3/8 in.)
Further scope of delivery as MaxiMAX

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:

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 chip board, coreboard 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

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 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

Danger Always observe the following safety instructions and the safety regulations applicable in the respective country of use!

General instructions:

Children and adolescents must not operate this machine. This rule does not apply to young persons receiving training and being supervised by an expert.
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.
When operating the machine outdoors, use of an earth-leakage circuit-breaker is recommended.
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

Do not use:

Damaged drill bits and drill bits that have changed their form.
Blunt drill bits as they impose an excessive load on the motor.
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.
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.
Do not reach under the workpiece.
Never support the workpiece in your hand or over your leg. Secure the workpiece against a sturdy support.
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.
Before starting to drill, tighten the drilling depth and cutting angle adjustments.
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.
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

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.).

Chip extraction

Selection of tools

Accessories”.
These carbide-tipped drills were developed specially for the DD40G/P and are suitable for all types of wood

Tool change

Danger
Pull the power plug during all service work.

The basic requirement for correct drilling are well ground drill bits. Proceed as follows for the tool change:

Turn the tool holding fixture 2 (Fig. 2) such that the screws 3 are on top.
Unfasten the screws with the Allen key.
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.
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)
Completely swing open the tilting stop 9.
Tighten the wing nut 11.
Place the machine with the swung open limit stop onto a flat surface.
Push the motor casing 5 forward until the tip of the drill bears on this surface.
Unfasten the wing screw 6.
Push the depth stop 7 up to the limit stop to the top and tighten the wing screw.
Push the indicator 8 to zero.

Pivot adjustment

Icon 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.
Tilt the tilting stop to the desired angle.
Retighten the wing nut.

Drill depth adjustment

Icon 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)
Push the depth stop 7 to the desired value.
Retighten the wing nut.

Adjusting the drilling clearance

Icon 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 the 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.

Clamp the workpiece or prevent it from moving by using the anti-slip mats supplied.
Position the machine on the workpiece and align the machine by means of the reference markings.
With your free hand, press the tilting stop against the workpiece.
Switch on the machine (see chapter 5.2) and push the motor casing forward up to the limit stop.
Pull back the motor casing and switch off the machine.

Drilling with stop pi

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.
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.
With your free hand, press the tilting stop against the workpiece.
Switch on the machine (see chapter 5.2) and push the motor casing forward up to the limit stop.
Pull back the motor casing and switch off the machine.

Drilling with additional stop

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.

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

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
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

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

EC Declaration of Conformity

We herewith confirm that the machine DD40 GIP 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

2006/42/EG 2014/30/EU 2011/65/EG DD40 G/P: EN 60745, EN 55014-1, EN 55014-2, EN 61000-3, EN 12100 T1, EN 12100 T2, EN 1037
Art.-Nr. 916001, 916002, 916010, 916020, 916021, 916025, 916030, 916031, 916032, 916035, 916040, 916041, 916042, 916045

Mafell AG: D-78727 Oberndorf, den 27.04.2016