DF500 issue: Excessive vibration & heat

[Jolly]

Hi Folks,

I bought my DF500 about two years ago, but barely use it.

Yep, shame on me, I'm a tool lover >_<

It's been well contained in systainer, and I vac off any dust on it before I store it.

I've been making some drawers for my wardrobe recently, and used DF500 to make some mortises.

I've discovered it started shaking and heating up after merely a couple of minutes of using.

And I found there's clear indication of friction between the moving part and the base.

It's still in warranty, so I believe FESTOOL will any way take care of this.

But I'm wondering if any of you have ever met this before, and if there's a quick fix.

Thanks for your attention.

 

[ChuckS]

Mine has a similar rub mark like that, and I suppose that is normal. No excessive shaking though, just some vibration from the motor. If you do a video, we can see how serious the "shaking" is.

I use this to lubricate the moving parts/housing:

 

[Jolly]

Mine has a similar rub mark like that, and I suppose that is normal. No excessive shaking though, just some vibration from the motor. If you do a video, we can see how serious the "shaking" is.

I use this to lubricate the moving parts/housing:

Thanks Chuck.

I feel they're not supposed to touch each other.

 

[Svar]

Does not look normal to me. I'll double check my later, but I haven't noticed any friction marks before. Does osculating part feel solid (not dropping down from the housing)?

 

[Jolly]

Does not look normal to me. I'll double check my later, but I haven't noticed any friction marks before. Does osculating part feel solid (not dropping down from the housing)?

Thanks, Svar.

The oscillating part feels pretty much solid, no sign of dropping down from the housing.

 

[ChuckS]

Searched a video via Google:=36

There you can see the wear mark on the fence body as well as on one edge of the underside of the spindle. I suppose as you plunge the cutter, the resistance from the wood might cause the moving spindle to lightly touch the fence body?

 

[Birdhunter]

I just checked my 500 and it’s a little shiny where the spindle shaft just barely touches the base. I just finished making a blue bird house using the 500 and I had no unusual vibration. The abrasion spot in your pictures is way more pronounced than on my 500.

 

[Distinctive Interiors]

Jolly,

You haven't stated whether you use your DF500 with a dust extractor connected....? Can you confirm?

The distance between the base plate and the oscillating arm is very small and it only takes a small amount of dust/chips to get in between the two surfaces...Hence, the reason I asked about the dust extraction.

 

[Svar]

[member=43373]Jolly[/member]  Just checked mine. No scratch marks, you can slide a piece of paper in between.

 

[ChuckS]

[member=43373]Jolly[/member]  Just checked mine. No scratch marks, you can slide a piece of paper in between.

That might explain the wear marks on some machines. Mine does not take a regular paper, only a thinner one.

 

[Jolly]

Searched a video via Google:=36

There you can see the wear mark on the fence body as well as on one edge of the underside of the spindle. I suppose as you plunge the cutter, the resistance from the wood might cause the moving spindle to lightly touch the fence body?

Thanks, Chuck.

I thought about that too.

I tested it in idle run, and same issue.

 

[Jolly]

Jolly,

You haven't stated whether you use your DF500 with a dust extractor connected....? Can you confirm?

The distance between the base plate and the oscillating arm is very small and it only takes a small amount of dust/chips to get in between the two surfaces...Hence, the reason I asked about the dust extraction.

I always connect every tool I have to my CT26, and it's virtually dust free.

Btw, I tested it in idle run, and the scratch happened as well.

 

[Gregor]

Btw, I tested it in idle run, and the scratch happened as well.

Service all included, it's there for a reason

 

[Svar]

If it was just scratching, you could file the aluminum part a bit. But it could also be a sign of another developing problem. Send it in for service.

 

[Jolly]

If it was just scratching, you could file the aluminum part a bit. But it could also be a sign of another developing problem. Send it in for service.

I have concern this would somehow destroy the calibrated balance of the oscillating part.

Sent to service, let's wait and see.

 

[Michael Kellough]

Looks excessive me too but how do the Dominos fit? Loose? Are they co-planer with the work surface?

 

[Jolly]

Guys, thanks to all for your input and suggestions.

A little bit of update:

Festool service representatives shows me a bunch of photos of DF500 at their hands, seems all suffering this 'issue'.

The explanation is: The housing of oscillator would expand a little bit due to heating up of the gearbox, thus touching the base plate.

The suggestion is: Just keep using it, and a couple of uses, 'issue' would be gone, meaning the oscillator and the base plate will make space for themselves after a certain period of rubbing with each other.

 

[Jiggy Joiner]

Guys, thanks to all for your input and suggestions.

A little bit of update:

Festool service representatives shows me a bunch of photos of DF500 at their hands, seems all suffering this 'issue'.

The explanation is: The housing of oscillator would expand a little bit due to heating up of the gearbox, thus touching the base plate.

The suggestion is: Just keep using it, and a couple of uses, 'issue' would be gone, meaning the oscillator and the base plate will make space for themselves after a certain period of rubbing with each other.

[blink]

 

[Svar]

Translation:  Festool did not allow for a proper clearance and now making excuses. Hey, your shoes don't fit? No worries, all our shoes are like that! Never mind the blisters, just keep wearing them...

 

[Michael Kellough]

If that’s all Festool will do about it then slip a piece of 600 grit abrasive in there and run it for a few seconds. Rotate the abrasive and repeat if necessary.

Or you could go after the bit holder (swing arm) directly. The thin piece of stainless (the base) is just a shield not a support so I don’t think there is a risk of removing too much from the swing arm, unless you use a grinder.