DTS 400 overheating(?) and shutting off

[raccoonhands]

My DTS 400 is shutting off after a couple minutes of use. It turns back on after a few minutes of rest. It feels warm to the touch so I think it may be overheating. (I've tried different cords with no effect.)

It is no longer under warranty. The last time I contacted Festool about an out of warranty sander for a wiggly cord connection, they had me send it in, told me it would be the same cost as a new tool to repair it, and when I declined the repair they sent it back to me in ten thousand pieces in a ziplock bag. I'm not eager to repeat that experience. Is there anything I can do to diagnose or troubleshoot the problem? I was going to see if there was a lot of dust accumulated inside, but it doesn't look like the pad assembly comes off very easily.

I very rarely use this sander but of course right now I have a project where it's critical  [blink]

 

[squall_line]

My DTS 400 is shutting off after a couple minutes of use. It turns back on after a few minutes of rest. It feels warm to the touch so I think it may be overheating. (I've tried different cords with no effect.)

It is no longer under warranty. The last time I contacted Festool about an out of warranty sander for a wiggly cord connection, they had me send it in, told me it would be the same cost as a new tool to repair it, and when I declined the repair they sent it back to me in ten thousand pieces in a ziplock bag. I'm not eager to repeat that experience. Is there anything I can do to diagnose or troubleshoot the problem? I was going to see if there was a lot of dust accumulated inside, but it doesn't look like the pad assembly comes off very easily.

I very rarely use this sander but of course right now I have a project where it's critical  [blink]

It is very likely overheating; the electronics protect against that.

To remove the main pad, there are 4 screws that come out and expose what you would need to see to determine the clog level.

If you still have the instruction manual, this is found on page 12.

If you don't still have it, here is a link to a PDF of the instruction manual:https://media.cdn.festool.io/productmedia/Images/attachment/bf0c4fae-c9e6-11ec-8127-005056b31774.pdf

Good luck!

 

[Cheese]

Look at the Plug-it individual pin connections both on the cord and on the sander. Is there any arcing or black marks...do they look like they are sparking? Do they feel loose when they're properly connected. Are they properly connected? There should be a hard stop when properly connected.

If yes, I'd replace both the internal connection on the sander and the Plug-it cord. Replace them both because one condition only exacerbates the other.

Kind of like chains & sprockets...on motorcycles.  [big grin]

 

[raccoonhands]

To remove the main pad, there are 4 screws that come out and expose what you would need to see to determine the clog level.

The area I can see when I remove the pad looks totally clear. There are four more screws there, but nothing else comes off when I remove them. Should it?

 

[raccoonhands]

Look at the Plug-it individual pin connections both on the cord and on the sander. Is there any arcing or black marks...do they look like they are sparking? Do they feel loose when they're properly connected. Are they properly connected? There should be a hard stop when properly connected.]

The connection feels sturdy and the cord and socket both look fine. I've tried three different cords :/

 

[squall_line]

How do the motor brushes look?  I wonder if there's additional resistance or arcing causing the overheating and/or general shutdown.

 

[raccoonhands]

How do the motor brushes look?  I wonder if there's additional resistance or arcing causing the overheating and/or general shutdown.

How do I get in there to see? After I take the pad off there are four more screws underneath, but removing them doesn't seem to loosen anything.

 

[woodferret]

Make your way all the way to Part #9 on the diagram.  That's the brush holder.
https://www.mmtoolparts.com/media/diagram/files/DTS400-EQ_493519.pdf

Easier from the top I think.

 

[raccoonhands]

Make your way all the way to Part #9 on the diagram.  That's the brush holder.
https://www.mmtoolparts.com/media/diagram/files/DTS400-EQ_493519.pdf

Easier from the top I think.

Thank you! I got in there are it was a little dusty, but nothing crazy.

Now it's shutting off after only 10-15 seconds of use and doesn't feel warm at all. I guess it's trash now? I can't image Festool would repair it for much less than the cost of a new one.

 

[woodferret]

Pull the brush.  Blow it out if it's not just left with a stub nubbin.  And try again.  That or buy a new $20 brush assembly.  I know the TS55 has some issue with brushes doing a false cutoff.  Might be the same with your DTS

 

[jonnyrocket]

Also, if you’re not familiar with how the brushes should look, post pictures once you get to them and we can be of better help.