Kapex just died

ChuckM said:
Kapex: "Home sweet home!"

May I add that if one plans to use any extension cord with the set-up you recommend, they should go with a 15amp cord under 25 ft. (I can't find any 20amp extension cord for that matter. I will be making one (10 ft long) for myself.)

[member=57948]ChuckM[/member]

You can get the LV one 12ga 15' 15A That's all you need. To get a 20A you will have to put it together using different sockets.

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From the pixture, if you look above the CT you will find a 20A 220v outlet and below a splitted 15a 110v. All my 110v receptacles are splitted (24).

P.S. Adding the iVac makes the CT run longer to clear debris. I believe the iVac runs 8 seconds after you turn off the power tool.
 

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I am seriously considering the KS120 miter saw & had concerns about the motor failures I have heard about on this forum. I also wanted to get more information as I know from experience most people, especially contractors don't read the manufacturers instructions :)

All too often I have seen contractors plug in their air compressors into a 100' long 16 gauge extension cord, then complain that the electric motor was junk because it failed in less than a year (see ohms law), rather than use the factory cord & use a long air hose (brilliant!).

I am aware that not all people use their miter saw alike. There are many variables to consider from material to application. Also, you need to consider the environment in which the saw would be used( clean, dry shop versus damp basement, filthy factory setting,or near the ocean with salt air, dusty or sandy environment) and the available power in that environment.

The Kapex, when used with a CT Dust Extractor, normally performs most cutting tasks (cutting molding) on a 15 Amp circuit without an issue whatsoever. For heavier cutting tasks (thick stock), it may be necessary to run the Kapex Saw (up to 13 amps) and the CT Dust Extractor (up to 10 amps) on separate circuits so that the saw has the full current of the circuit available. Otherwise you are overloading the electric motor.

This saw does not have your basic motor, it has Processor controlled “Multi Material Control” power electronics, that provide adjustable and constant speeds as well as temperature monitoring for work on all types of material. An electronically load detection controlled motor that will adjust the blade speed according to the load. In other words, yous saw motor has a computer! The plus side is the benefit of regulated constant speed regardless of the load, the down side it is sensitive to input voltage & load. While most of us fail to do so, all electrical equipment should be unplugged when not in use, if for no other reason lightning strikes. You can buy a hole system to protect your tools, or just unplug them. You can also buy electrical outlets with a switch. I wouldn't recommend a power strip, as it is most likely not rated for the amperage your saw is using.

In closing, it seems that the vast majority of KS120 miter saws perform as expected & there is a possibility that the few failures were the users responsibility??? Not making accusations, just trying to make sense of this issue. If there were a known problem, I would expect many more folks having the exact same issue. Saying that my old Dewalt, or Makita never had this trouble, really isn't relevant as we don't know if the use was the same & we know for sure the motors are very different. I wonder how many people have had issues with this saws moter, versus how many people are very happy with their purchase?

 
Welcome to the FOG.....just so you know you aren’t preaching to an uneducated group on this subject...the ks120 (and it’s problems) has been hashed over more than a few times but with your knowledge even if you had a burn out, sounds like you’d have no problem swamping out another motor like a few here have done successfully 
 
“While most of us fail to do so, all electrical equipment should be unplugged when not in use, if for no other reason lightning strikes”

That’s a new one re the Kapex, but true enough.
 
I know that this thread is ancient, but this info might help.

I have been running my Kapex for almost 8 years.  Over 90% of the time it runs through a Fein vacuum.  I was blissfully unaware of Kapex motor failures until I happened upon this thread.

I have had no motor problems.  I think that the Fein is sending most of the power to the saw - the vac sounds like it slows a bit when the saw is drawing power.

I tested with a Killawatt.  I go the same readings going to the saw from both the vacuum outlet and direct from the wall.  About 7.5-8 amps idle and about 12-16 amps cutting combination of a 2x6 and 3/4" mdf.

My Fein is an older model 9.20.25 Turbo II.  Running with a Dust Deputy.

It may be that the CT vacs are part of the problem for some.
 
Pretty sure (I’ve read here third hand) some saws plugged directly to their own circuit have also gone up in smoke.
 
Michael Kellough said:
“While most of us fail to do so, all electrical equipment should be unplugged when not in use, if for no other reason lightning strikes”

That’s a new one re the Kapex, but true enough.
Makes sense for a CT and a Kapex, as the former likely stays in auto while the latter dosn't have a primary power switch so the power supply for the electronics (and lasers) is always active.

On the other hand adding graduated surge protection in your mains panel will protect your whole house from what might be trying to come in from the main line, direct lightning strikes are rare (and will give you more interesting problems to deal with anyway) so these can basically be ignored.
 
Has anyone else ever had to replace a arbor or bushing/bearing on a Mitersaw that is less than 5 years old ?

I've never had to replace those on any mitersaw. Ever.  I think it a travesty that the most expensive saw on the market would even need those replaced at all; let alone charge the customer for them on a machine with known issues.
 
I own two of the Kapex units without any problems but they are not put under heavy stress. I like the Festool product as a whole and own many products BUT

FYI you must use any German-designed product with a tender touch like german cars.

So when you mix a regional design flaw into the system the tenderness goes up for that product.

Now I see the design problem in the Kapex as an electrical issue. When you design this kind of product you must consider many things but dealing with the heat produced when stress loading the design is a major concern.

I design all Hi stress loaded products by the voltage used to provide power to that product for a given loading length of time.

We must remember Germany is 220 volts and this 220 will give you certain amps to produce certain work.

When you drop voltage tp 120 you get certain amperage for the same work but much higher amps needed to produce the same work as 220 volts would give you.

Asking for Amps = HEAT

So I always provide more heat removing design in the system with lower voltage.

I think Festools products are designed for 220 volts and producing then for 120-volt use can be a challenge if you have a production budget. It can be done and the electrical staff can do it but at what cost.

When designing products that need to operate a lower voltage you must reduce the loading or increase the heat handling removing systems in the design. This is not an option if you wish to provide a reliable product.

Just my thoughts

Rick

Just ask the aviation electrical motor designers they must work with very low voltage as low as 28 volts in very continuous hi stress environments WOW.

 
I have to disagree, I am known for looking after things, especially tools but, I don’t baby anything, it gets used in the manner it was designed for. When cutting timber, especially thick hard timber, with a mitre saw, there’s no tender touch involved.

I own other makes of German tools, and many possessions that are German built, no tender touch or kid gloves there either.
The Kapex failures were because of a batch of certain parts, it’s documented on this site and elsewhere.
Forget low voltage versions too, there have been failures with the 240 v Kapex too.

Festool finally admitted there was a potential issue with some Kapex’s that had certain parts fitted. They say the problem is now resolved with upgraded parts.
 
Festool should do a recall like what they do in the auto industry. My previous Honda Pilot (2003) had undergone five recalls (three related to the airbags) and all issues identified were fixed by the dealership -- free of charge, of course. It was Japanese, not even Germany!

Replace the old parts with the upgraded parts...and everybody will be happy.

P.S. Tarnished reputation repaired (assuming the upgraded parts do the job as claimed).
P.P.S. And this thread would die by itself if Festool did the honorable thing -- not holding my breath.
 
ChuckM said:
Festool should do a recall like what they do in the auto industry. My previous Honda Pilot (2003) had undergone five recalls (three related to the airbags) and all issues identified were fixed by the dealership -- free of charge, of course. It was Japanese, not even Germany!

Replace the old parts with the upgraded parts...and everybody will be happy.

P.S. Tarnished reputation repaired (assuming the upgraded parts do the job as claimed).
P.P.S. And this thread would die by itself if Festool did the honorable thing -- not holding my breath.

I like everyone else on the forum wishes that Kapex failure threads would die a natural death.  But that isn't going to happen easily.  But the truth is that the actual number of posts by those who are having an issue (compared to those who just want to talk about the situation) has dramatically decreased.  Attribute that to whatever you want to.  But that is a fact.

Comparing a tool failure issue over time to a Federally mandated recall in an industry (automotive) that is highly regulated is not an apples to apples situation.

Product failures are not usual and those on the failure end are never happy.  I wouldn't be either if my Kapex had gone rouge on me.  But even Rolls Royce, Bentley, Ferrari, Mercedes, Ford, Chevrolet... and any other high priced items do not have a lifetime warranty which is basically what so many want.  I would love for Ford to replace my 5.4 liter engine in a now dormant truck due to the design issues with that engine that was then produced for eons and put into a million or more vehicles.  I decided holding my breath would lead to my early death and decided to move on.

Just my thought and opines.

Peter
 
Peter Halle said:
Comparing a tool failure issue over time to a Federally mandated recall in an industry (automotive) that is highly regulated is not an apples to apples situation.

Peter

I chose my words carefully:

"...if Festool did the honorable thing...."
I did not suggest it was a legal-binding/obligatory responsibility.

 
JCLP said:
My Kapex just died. Strated blowing my circuit and now won't even spin. Definitely an electrical issue with the motor. Anyone know the number for Canada service?

Almost to the day, purchased Mar 25, 2014. 1 year past warranty. Middle of a kitchen project, now what do I do. This will take at least 2 weeks to ship, fix and ship back. Last thing I want to do is buy another one for these two weeks. Thank goodness I kept the box.

JC
Go get the makita 10" slider.  The one that can be butted against the wall.

Sent from my SM-G973U using Tapatalk

 
The Kapex failures were because of a batch of certain parts, it’s documented on this site and elsewhere.

Really - Where ?

I've followed this since the beginning and don't recall seeing such documentation.  I do remember Festool denying there was a problem.  Then telling everyone that they must have failed because they were used to cut small/thin material.  I'm a bit fuzzy on the next bit though.  There has been a re-design, but I don't think Festool has specifically said there was a problem. 

Which is two different things even if they are related.

Festool finally admitted there was a potential issue with some Kapex’s that had certain parts fitted. They say the problem is now resolved with upgraded parts.

see above - can you provide the link to their admission? 

And sorry, but I'm just not willing to "take their word for it" after their outright denial to start with.  Furthermore - how do you ,or even Festool, know whether the "upgrade" is going to solve the issues ?  You can't, and I'm skeptical they have the capacity or even wherewithal to have stress tested the new motors on 110v for long enough to know for sure either. 

Remember this is the same company and group of engineers that designed the first faulty motor ( which presumably was also tested with no problems )  and then couldn't find said issue when reports started surfacing.  That faith doesn't seem very rational to me.

 
If you are not trusting FESTOOL with their Kapex handling, don’t get it.  Simple as that.  If you think the cost is justified and “trust” their upgrades motor, then take the plunge.  I took the plunge and have been happy so far. 
 
xedos said:
The Kapex failures were because of a batch of certain parts, it’s documented on this site and elsewhere.

Really - Where ?

I've followed this since the beginning and don't recall seeing such documentation.  I do remember Festool denying there was a problem.  Then telling everyone that they must have failed because they were used to cut small/thin material.  I'm a bit fuzzy on the next bit though.  There has been a re-design, but I don't think Festool has specifically said there was a problem. 

Which is two different things even if they are related.

Festool finally admitted there was a potential issue with some Kapex’s that had certain parts fitted. They say the problem is now resolved with upgraded parts.

see above - can you provide the link to their admission? 

And sorry, but I'm just not willing to "take their word for it" after their outright denial to start with.  Furthermore - how do you ,or even Festool, know whether the "upgrade" is going to solve the issues ?  You can't, and I'm skeptical they have the capacity or even wherewithal to have stress tested the new motors on 110v for long enough to know for sure either. 

Remember this is the same company and group of engineers that designed the first faulty motor ( which presumably was also tested with no problems )  and then couldn't find said issue when reports started surfacing.  That faith doesn't seem very rational to me.

I have colleagues who have experienced Kapex failures, these are tradesman like myself that use power tools daily. They are used with respect and care, but not wrapped in cotton wool.
The majority of failures I have personally experienced, are 110v probably because in the UK they like us to use 110 on site but, I have also experienced one company that owned four 240 v Kapex’s and two of their saws had failed twice, and fixed under warranty, and also one of those saws failed a third time.

The saws were/are used for cutting flooring up to around 20mm thick, and small beading and trim, nothing more. His guys have like 20-30 years of experience. They know how to use a mitre saw.
Yet the saws randomly failed.

I have seen the other side of things, where trades have turned up on site, with absolutely battered Kapex’s. Broken blade guards, blunt blades, badly marked tops and fences, even holes in the casings.
These saws have been clearly abused. I asked one such guy (about 2 years ago) how long he’d owned the saw, he replied since they first came out. He had one warranty claim on it, not from motor issues though, it was the blade guard and mechanism.
The people certainly didn’t treat or respect their tools properly, yet the motors were going strong.

I have for many years owned a lot of Makita tools, also some Mafell, Hilti and Festool.
My mitre saws have been mainly Elu/De Walt and Makita, and one or two random one offs from other manufacturers. I never had any issues from any of the mitre saws, apart from the usual brush replacement, and the usual expected consumables.

I was hearing or seeing Kapex’s failing a fair bit. Not every day, or every week but, every so often I’d hear or be told about another failure.
So after quite some time, I figured there must be an issue with the saws, and in view of the cost of one, I was a bit miffed why people bought them.

I kept hearing how good they are, well at least until they failed. Many colleagues told me to buy one and I’d never look back, no thanks I’d reply, pay out all that money and worry about smoke pouring out of it.
I even told of my experiences, and low opinion of the situation on this site and some others.
I had a new chap start with us, and he owns a lot of Mafell and Festool kit. He as a Kapex 120 EB.
I immediately ribbed him about the saw, saying we have a spare mitre saw for when his develops a smoking habit. He took it in the way it was meant, a bit of banter. He then said he’d not buy any other saw when the time came to replace it, it was that good. Even most of the owners of failed saws told me the same, which got me thinking.

Anyway, he worked alongside me for a while, and told me to feel free to use his Kapex instead of getting my saw off the van. I couldn’t resist to be honest, and in a very short time, I learned what all the fuss was about, and why these saws are held in such high regard.
The vertical handle took some getting used to, and the motor tone isn’t like that of any other saws I’ve owned, even the latest 120 REB sounds similar.

Quite some time later, we needed to buy a new mitre saw, I was now hankering after a Kapex but, all the stories and experiences I’d had was preying on my mind.
I spoke to different dealers asking if the issues were now sorted, usually the replies were “what issues”
Then after a lot of digging I spoke to some more honest dealers, and somebody who was quite high up at Festool, that the issues were real, and related to certain batches of parts.
So some machines had the potential to fail, and depending on what batch of parts were used to repair them, had the potential to fail again.

So, any older model 120 EB machines, I think after October 2017 were fitted with upgraded parts.
This may of been a guinea pig test who knows?
Apparently much testing was carried out, and Festool were happy with the results, and released the latest Kapex 120 REB, also fitted with the upgraded parts.

There was no announcement at the time from Festool, who seemed to be sticking to the “what problem” stance. This is what seems to have upset so many Festool owners including myself. They obviously knew there was an issue, albeit a minority percentage, just by the warranty claims they were dealing with? If they had been more transparent, I’m sure customers would have felt their intelligence wasn’t being insulted. Perhaps at the time, because they didn’t have a fix, they decided to play it down? Either way, they were wrong in my opinion.

I went on to buy the latest 120 REB just after release. It has been a great saw so far, I honestly cannot fault it and don’r regret the purchase, I even recommend it to friends and colleagues.
Too early to say if it will stand the test of time, if it fails in warranty, it will get fixed no charge. If it fails out of warranty, I will put it down to an expensive mistake, I certainly won’t lose sleep over it, as there’s far more important things to worry about than a broken saw.

Festool decided to finally come clean about the issues, way too late in my opinion but, better late than never I guess.
This is documented here and in other media and sites if you search.

Here is one example:https://www.festoolownersgroup.com/festool-announcements/message-from-festool-about-kapex-miter-saw/

I’m sure you can search for yourself, for any other snippets or info, or speak to a trusted dealer, or even call up Festool and discuss it. When I did this, It was confirmed to me.

I’m personally satisfied that this is true, and is about as much as we’re going to get from Festool regarding the matter. It would as others have mentioned, been good for owners of the earlier saws, to get a recall and have the upgraded parts fitted. Festool maintain it is only certain saws, with a certain batch of parts fitted that are at risk though. Which might explain why so many old, out of warranty saws are still going strong?

So, I’m happy to carry on as a Festool customer, and move on.

So forget all about voltage, or babying, it has nothing to do with it. As the poster above advised, if you’re not happy with Festool, or don’t trust them, move on and buy alternative offerings.
 
ChuckM said:
Festool should do a recall like what they do in the auto industry. My previous Honda Pilot (2003) had undergone five recalls (three related to the airbags) and all issues identified were fixed by the dealership -- free of charge, of course. It was Japanese, not even Germany!

Replace the old parts with the upgraded parts...and everybody will be happy.

P.S. Tarnished reputation repaired (assuming the upgraded parts do the job as claimed).
P.P.S. And this thread would die by itself if Festool did the honorable thing -- not holding my breath.

You know, I don't agree with this stonewalling approach, but it seems to be the way of the world when a problem is NOT safety related.  Since you brought up Honda, look up the oil dilution issue with the 1.5L turbo motors.  I currently own one and their handling of this might make this my last Honda.  It's hard to single out Festool when it really is a more systemic issue with companies peddling consumer goods.
 
Hello All:

How many dollars does it cost to get a repair completed using Festool service?

Can you purchase the necessary parts and perform the work yourself?

Rick
 
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