Mafell ZB 100 ES Carpentry Drilling Machine

Important Safety Information

This operating manual contains important notes for safe working practices with this machine. It is therefore essential that you read these operating instructions carefully.

Symbols Used:

• ⚠️ Warning: Indicates notes for your safety. Disregarding these may result in very serious injuries.
• ⚠️ Hazard: Indicates a potentially hazardous situation. Disregarding this may result in damage to the product or objects in its vicinity.
• ℹ️ Information: Indicates tips for the user and other useful information.

The document also includes warnings in German, French, and Italian.

1 Product Information

1.1 Manufacturer's Data

Company: MAFELL AG

Address: P. O. Box 1180, D-78720 Oberndorf / Neckar

Phone: +49 7423 812-0

Fax: +49 7423 812-218

1.2 Machine Identification

All data required for identification are stated on the rating plate attached to the motor casing.

• Protection class II
• CE-mark: Declares conformity with essential health and safety requirements according to Annex I of the Machinery Directive.
• Only for EU countries.

Environmental Note: Do not dispose of electric tools with household waste. Electric tools reaching the end of their life must be collected separately and returned to an environmentally compatible recycling facility, in observance of European Directive 2002/96/EC.

1.3 Technical Data

1.4 Noise Emission

Noise emission values determined according to EN 60745-1 and 60745-2-1:

Note: Measurements do not account for series variance or specific operating conditions. Immission sound power levels vary by user environment.

1.5 Vibration

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

1.6 Delivery Specification

The Carpentry Drilling Machine ZB 100 ES is supplied complete with:

• 1 mains cable 10 m / 33 ft (5 m / 16.4 ft for CH)
• 1 special drill mount
• 1 mounting shaft 039 192
• 1 operating manual
• 1 folder «Safety instructions»

1.7 Use According to Intended Purpose

The MAFELL carpentry drilling machine ZB 100 ES is intended exclusively for cutting operations on solid timber using head countersinks and ring-groove drilling tools, in conjunction with the supplied special drill mount 039160. Tools must correspond to MAFELL specifications.

Any use beyond this scope is considered misuse. The manufacturer is not liable for damage resulting from misuse; the risk is borne by the user.

The machine is not suitable for outdoor operation in rain or in areas subject to explosion hazards.

Proper use includes adherence to operating, maintenance, and repair conditions specified by MAFELL, and following safety instructions.

The machine may only be used, set up, and serviced by persons over 18 years of age who are familiar with the machine and its dangers. Repairs must be carried out by authorized MAFELL dealers or service stations.

Country-specific safety regulations and general occupational medicine rules must be observed. Unauthorized modifications void manufacturer liability.

1.8 Residual Risks

Residual risks may exist even when the machine is used properly and in compliance with regulations. These include:

• Touching running tools or tool mounting.
• Breakage of tools.
• Hurling away of incorrectly inserted knives.
• Breakage and hurling away of knife pieces.
• Touching sharp knives when the tool is not running.
• Touching sharp cutting edges when changing knives.
• Touching live parts with the housing open and the mains plug connected.
• Hearing impairment from prolonged use without ear protection.
• Emission of wood dust, a health hazard without dust extraction.

2 Safety Instructions

Woodworking machines can be dangerous. Always follow the safety instructions and applicable country-specific regulations.

General Instructions

• Never work without prescribed protective equipment or make safety-compromising modifications.
• Children and young persons must not operate this machine, except for supervised training of persons over 16 years old.
• Electrical components should only be serviced by a trained electrician.
• Before starting work, ensure all safety and operating equipment is securely attached and undamaged.
• Be aware of environmental influences; do not expose the machine to rain, damp, wet environments, or flammable liquids/gases.
• Operate the machine only outdoors or in well-ventilated areas where chip and dust extraction is possible.
• Use of an earth-leakage circuit-breaker is recommended for outdoor operation.
• Do not carry the machine by the cable; do not remove the plug by pulling the cable.
• Protect the cable from oil, high temperatures, and sharp edges.
• Replace damaged cables or plugs immediately.
• Avoid sharp cable bends; do not wind the cable around the machine during transport or storage.
• Only use MAFELL tools listed in the price list.
• Do not use damaged or blunt tools.
• Store the machine dry, locked, and out of reach of children.

Instructions on the Use of Personal Safety Equipment

• Always wear close-fitting industrial clothing. Remove rings, bracelets, and watches.
• Wear ear protectors, as the sound pressure level can exceed 85 dB (A).

Instructions on Operation

• Provide an uncluttered, anti-slip location with adequate illumination.
• Before tool changes or clearing malfunctions, pull out the mains plug.
• Never work with workpieces that are too large or too small for the machine's capacity.
• Ensure the machine is switched off before connecting to the mains.
• Before switching on, verify the tool and knives are correctly clamped.
• Hold the machine firmly before switching it on.
• The bolt for the torsional force stop must fully contact the workpiece. Insufficient contact can cause slippage, leading to the machine or workpiece being hurled away.
• Secure the workpiece against slipping and tipping over whenever possible (e.g., with screw clamps).
• Do not begin cutting until the saw blade reaches full speed.
• Examine the workpiece for foreign objects; never cut nails or metal objects.
• Keep hands well away from the running tool or tool mounting.
• Keep hands away from the underside of the workpiece when cutting (risk of injury).
• When cutting, lead the cable away from the machine to the rear.
• Match the feed rate to the cutting diameter and depth. Excessive feed rates overload the motor, result in poor cuts, and blunt tools prematurely.
• A uniform feed rate increases tool and machine life and reduces accident risk.
• Knives must be reversed, sharpened, or replaced promptly; blunt knives increase kickback risk and motor load.
• Do not remove the machine from the workpiece until the tool is stationary.

Instructions on Service and Maintenance

• Regular cleaning of the machine, especially the tool mounting, is crucial for safety. Pull out the mains plug before cleaning.
• Only original MAFELL spare parts and accessories must be used. Use of non-original parts voids warranty and manufacturer liability.

3 Setting up / Adjusting

3.1 Mains Connection

⚠️ Important: Machine must be switched off before connecting to the mains.

The ZB 100 ES has Class II protective insulation (double-insulated). Before starting up, ensure the mains voltage matches the rating plate voltage.

3.2 Mounting and Exchanging Tools

⚠️ Important: Always pull out the mains plug before changing tools.

• Lift sleeve 7 (Fig. 1) until the ring groove 8 around the arbor is visible. Insert the drill bit as far as it will go, aligning the flat end with the two small grooves 9 at the arbor end. Release the sleeve.
• To exchange a drill bit, hold it, lift sleeve 7 until the ring groove is visible, remove the drill bit, and release the sleeve. Ensure the drill bit shaft and arbor surface are clean before inserting a new bit.

4 Operation

⚠️ Important: Do not switch on the machine if the drill bit is touching the workpiece.

4.1 Switching On and Off

• Temporary Operation:
• Switching on: Press switch 1 (Fig. 2).
• Switching off: Release switch.
• Continuous Operation:
• Switching on: Press switch 1, then press locking button 2. The motor runs without holding the switch.
• Switching off: Press switch 1 until locking button 2 trips, then release the switch.

4.2 Adjusting Drilling Speed

This drilling machine features a gearbox and electronic speed control, allowing continuous adjustment between 340 and 1450 rpm. The electronics ensure smooth acceleration and maintain set speed.

Select the required drilling speed based on diagramme 3 (Fig. 2) and set it using the gear shift lever 4 and setting wheel 5.

⚠️ Important: Gear shifting should only occur when the motor is switched off and the machine has stopped or is coasting down (see Fig. 4). Check drill bit rotation direction after switching on. If necessary, change direction using reversing switch 6 (Fig. 2); ensure the motor is off before actuating the reversing switch, as it is mechanically blocked.

4.3 Operating Instructions

Bolt 10 (Fig. 2) should be pushed down as far as possible and fastened with clamping screw 12. Position the machine so the guide pilot pin of the cutting tool enters the hole in the timber. Turn the machine until the bolt touches the timber to act as a stop for torsional force. Push the machine down after switching it on. Cutting depth can be set using the depth stop ring 11.

4.4 Tools

For head countersinks and ring-groove drilling tools, refer to the price list. Special leaflets are available upon request.

5 Service and Maintenance

⚠️ Important: Pull out the mains plug before starting any maintenance work!

MAFELL machines are designed for low maintenance. Ball bearings are greased for life. For prolonged operation, it is recommended to have the machine checked by an authorized MAFELL customer service shop.

5.1 Machine

Clean dust deposits from the machine at regular intervals, including the motor air vents using a vacuum cleaner.

5.2 Tools

Drill bits must be regularly freed from resin to ensure good drilling quality.

5.3 Storage

If the machine is out of service for an extended period, clean it thoroughly (see chapter 5.1). Spray bright metal panels with a rust-proofing agent. Store the machine in dry rooms, protected from weathering.

6 Troubleshooting

⚠️ Caution: Determining and eliminating defects requires attention and caution. Pull out the mains plug beforehand!

The following chart lists common defects, causes, and eliminations. For other defects, contact your dealer or MAFELL customer service.

7 Optional Accessories

• Supplementary handle, cpl. (Ref. No. 039 203)

8 Exploded Drawing and Spare Parts List

Information regarding spare parts can be found on the MAFELL homepage: www.mafell.com.