Kapex KS 120 EB blade clicking

[asch128]

Hi -

I am a recent owner of a Kapex KS 120 EB miter saw and have run into an issue. The blade does not spin freely and I hear a clicking noise when I manually spin the blade with my hand. It is as if it is clicking through gears - see video clip of issue here -> https://photos.app.goo.gl/4xrqrfP51xiSZU3A8

When I turn the saw on, the blade continues to make the clicking noise and the saw turns off after a few seconds of running. I cannot visually see that it is binding on anything and it sounds like the noise if coming from up toward the top of the handle/motor area. I did remove the blade and reinstall to see if that would help anything and it did not. I also removed the dust port in the back and that did not help either.

Anyone ever run into this issue? More importantly, anyone know how to fix this issue or what the root cause is? Really hoping for user error here....

Thank you!

 

[squall_line]

I watched the video, thank you for posting that.

I can't tell if it's hitting the blade guard or if there's a stripped gear inside.  Does the blade guard vibrate when you manually turn the blade?

Either way, I cannot recommend highly enough that you leave the saw unplugged and don't engage the motor under power again until you get the issue resolved.  There is almost literally nothing going on in that video that is going to just work itself out without the possibility of serious injury to you or your property or others around you.

 

[Bohdan]

Could it be the blade lock being partially engaged.

 

[asch128]

I can't tell if it's hitting the blade guard or if there's a stripped gear inside.  Does the blade guard vibrate when you manually turn the blade?

I can confirm it is not hitting the blade guard and it does not vibrate when I manually turn the blade. A stripped gear sounds possible - would I be able to see this if I remove the cover for the motor? If so, is this a DIY fix?

Could it be the blade lock being partially engaged.

It's possible this may be happening - I do have the trigger fully engaged though but maybe something on the inside it preventing it from fully engaging.  Is there a way I can see if this is the case or not? Maybe take the cover off?

 

[squall_line]

You said that this was a recent acquisition.  Is it a used tool?  Does it fall under any sort of warranty (I know it's an EB instead of an REB, but the newest EBs from 2018 should still have at least a few months left on a warranty)?

If it's still under warranty, there is no sense in attempting a DIY fix; get it back to Festool and let them repair it.

If it's no longer under warranty, it's still better to at least get it to an authorized dealer who may be better equipped to answer the question.

Even if it's used, if it did this the first time you attempted to use it, have you contacted the previous owner to see if they had any issues with it before they sold it?

Without knowing your own comfort level and particular area of experience and expertise, I can't say whether this is a DIY fix or not.  I would still exhaust warranty-related options first, personally.

 

[asch128]

You said that this was a recent acquisition.  Is it a used tool?  Does it fall under any sort of warranty (I know it's an EB instead of an REB, but the newest EBs from 2018 should still have at least a few months left on a warranty)?

Yes, I bought it used and, if I remember correctly, I believe the previous owner said it was about 8-10 years old.

If it's still under warranty, there is no sense in attempting a DIY fix; get it back to Festool and let them repair it.

I e-mailed Festool customer service and all they said was to send them the tool and didn't offer any general troubleshooting. I also asked if I could drop the tool off directly at their location but they said that was not an option due to COVID and the tool had to be shipped - I don't live in Indiana but will happen to be in Indiana in a few weeks. I'm  frustrated they won't let me drop it off and are forcing me to pay shipping.  Ugh!

If it's no longer under warranty, it's still better to at least get it to an authorized dealer who may be better equipped to answer the question.

Do all authorized dealers 'fix' Festool products? Eg: I live near a Woodcraft - are they equipped to service a Kapex or are they just there to offer general advice?

 

[squall_line]

If it's no longer under warranty, it's still better to at least get it to an authorized dealer who may be better equipped to answer the question.

Do all authorized dealers 'fix' Festool products? Eg: I live near a Woodcraft - are they equipped to service a Kapex or are they just there to offer general advice?

I don't believe that they can actually repair anything in the shop, but if it's out of warranty, they can theoretically do anything they want/are comfortable with.  I don't know what the official agreement is between FUSA and their dealers in that regard.

If nothing else, the folks at Woodcraft may be able to tell you if they've ever seen the issue you're experiencing and help point you in the right direction if they know of an easy fix.  Their depth of knowledge may not be as deep as the total combined knowledge and experience of the FOG, but you never know who is going to read this message and when they'll read it.  At Woodcraft, you'd at least have an answer fairly quickly, depending on the distance to get there.

 

[ChuckM]

I e-mailed Festool customer service and all they said was to send them the tool and didn't offer any general troubleshooting. I also asked if I could drop the tool off directly at their location but they said that was not an option due to COVID and the tool had to be shipped - I don't live in Indiana but will happen to be in Indiana in a few weeks. I'm  frustrated they won't let me drop it off and are forcing me to pay shipping.  Ugh!
[/quote]

At the height of the pandemic, some merchants would not even allow their staff to enter a customer's house. Virtual install or inspection was the only option! I've not physically seen my family doc for a long time -- everything is done over the phone. I call him and he calls back. Medication and lab tests? All prescribed or booked electronically for me by his office. I kinda like it, cutting waiting times and trips to his office.

Would it be cheaper if you drop ship in Indiana when you're there?

One question: Did you test run the saw before the saw was handed over to you?

 

[asch128]

At the height of the pandemic, some merchants would not even allow their staff to enter a customer's house. Virtual install or inspection was the only option! I've not physically seen my family doc for a long time -- everything is done over the phone. I call him and he calls back. Medication and lab tests? All prescribed or booked electronically for me by his office. I kinda like it, cutting waiting times and trips to his office.

Yeah, I hear ya - some changes are for the better. I respect their decision even though I don't agree with it.

Would it be cheaper if you drop ship in Indiana when you're there?

Not a bad idea - thank you for the suggestion. I may consider this if I can't DIY a fix.

One question: Did you test run the saw before the saw was handed over to you?

Yes, but to be honest I wasn't paying too much attention. I was too excited because he sold me an almost brand new 3HP SawStop with a bunch of add-ons for about 50% off retails from the same guy as well as a bunch of other stuff - I didn't peg him as one to pull a fast one on me. He was exceptionally nice and even called me back after he found some additional extras for the SS that I could have. I didn't turn the Kapex on for about 4ish weeks since getting it so I have no one to blame except myself. 

 

[squall_line]

One question: Did you test run the saw before the saw was handed over to you?

Yes, but to be honest I wasn't paying too much attention. I was too excited because he sold me an almost brand new 3HP SawStop with a bunch of add-ons for about 50% off retails from the same guy as well as a bunch of other stuff - I didn't peg him as one to pull a fast one on me. He was exceptionally nice and even called me back after he found some additional extras for the SS that I could have. I didn't turn the Kapex on for about 4ish weeks since getting it so I have no one to blame except myself.
[/quote]

He may not have been trying to pull a fast one, it may be something that happened during transport, too.

Happens to the best of us.

I'll admit, I purchased a few power tools used from someone and only turned on one of them before I handed over the cash and drove off.  In retrospect, if I was going to only turn on one of two items that I was buying used, I probably should have turned on the more expensive one.  [blink]

Come to think of it, I don't know if I've still turned that other tool on yet.  Yet another chore for tonight, I suppose.

 

[serge0n]

[member=76288]asch128[/member] is your FastFix selector for the blade change in the correct position? Turned all the way to the left? If it's not the saw will not work, it's a safety feature.

The blade change mechanism in Kapex is pretty crappy and relies on a tiny piece of plastic that blocks blade rotation. That piece can break off easily, maybe yours broke off and lodged itself in a way that prevents the saw from working properly. If that's the case just take off the motor cover and take a peek inside. I had to replace mine once.

My Kapex is over 13 years old, has the same clicking sound when you turn the blade manually, but works just fine.

 

[asch128]

[member=76288]asch128[/member] is your FastFix selector for the blade change in the correct position? Turned all the way to the left? If it's not the saw will not work, it's a safety feature.

FastFix selector? Is this the round knob/dial just past the handle? See attached picture...

[member=76288]asch128[/member]
The blade change mechanism in Kapex is pretty crappy and relies on a tiny piece of plastic that blocks blade rotation. That piece can break off easily, maybe yours broke off and lodged itself in a way that prevents the saw from working properly. If that's the case just take off the motor cover and take a peek inside. I had to replace mine once.

The knob is still there and seems to turn as I would expect. I will definitely check this out later tonight though to see if there is something behind the curtains that may not be working or broken. I will report back...

[member=76288]asch128[/member]
My Kapex is over 13 years old, has the same clicking sound when you turn the blade manually, but works just fine.

Good to know! I did turn it on two times to see if it would go away and the saw turns on for a few seconds and then turns off - the grinding/clicking noise persists while the saw is turned on.

 

[serge0n]

[member=76288]asch128[/member] is your FastFix selector for the blade change in the correct position? Turned all the way to the left? If it's not the saw will not work, it's a safety feature.

FastFix selector? Is this the round knob/dial just past the handle? See attached picture...

That's the one. It should be turned all the way to the left.

My saw also has the grinding noise when I start it. I always thought it was normal for Kapex. Can someone else chime in, should we hear the grinding noise when Kapex is running?

 

[serge0n]

This is nuts - out of dozens of Kapex videos on YT it was really hard to find any that demonstrated how the saw was actually cutting and what sound it was making!

I finally found one, the grinding sound appears to be the norm as I have suspected:

 

[asch128]

I confirmed the FastFix selector is turned all the way to the left.

Thank you for the video - this does help confirm the noise/grinding.....but....

I turned the saw on again tonight and it runs for a few seconds and then turns off by itself - see video ->https://photos.app.goo.gl/4Jn7M45qiGNMy5hX8

Any ideas on the problem here? I am fully engaging the trigger and not releasing it at all. The saw is plugged directly into a 20amp outlet by itself. Is something overheating?...in such a short amount of time? Is a safety measure of sorts kicking in? I'm stumped here!

Any advice is much appreciated!

 

[ChuckM]

Hi -

I am a recent owner of a Kapex KS 120 EB miter saw and have run into an issue. The blade does not spin freely and I hear a clicking noise when I manually spin the blade with my hand. It is as if it is clicking through gears - see video clip of issue here -> https://photos.app.goo.gl/4xrqrfP51xiSZU3A8

I just tried, but I couldn't find a way (tried all kinds of combinations) to turn the blade by hand as you did in your clip. The blade is always locked unless I power it on.

 

[ChuckM]

I confirmed the FastFix selector is turned all the way to the left.

Thank you for the video - this does help confirm the noise/grinding.....but....

I turned the saw on again tonight and it runs for a few seconds and then turns off by itself - see video ->https://photos.app.goo.gl/4Jn7M45qiGNMy5hX8

Any ideas on the problem here? I am fully engaging the trigger and not releasing it at all. The saw is plugged directly into a 20amp outlet by itself. Is something overheating?...in such a short amount of time? Is a safety measure of sorts kicking in? I'm stumped here!

Any advice is much appreciated!

Someone seemed to have encountered something similar: Spudfish:
It slows down and then comes to a casual stop like it would if let go of the trigger.

https://www.festoolownersgroup.com/festool-tool-problems/kapex-slowing-down-after-start/?wap2

 

[asch128]

Hmm...does seem similar. My tachometer is in place though. I removed the motor cover and see no issues - no loose connections, no burning smell, nothing looks odd, etc - see pics.

 

[serge0n]

Check the brushes, maybe they are worn out? Another place to check is the switch, I would disassemble the entire blade cover to get to all the components inside. It's not hard at all, maybe just a little bit tricky to get it back together.

And I stand corrected, the piece that blocks the blade from spinning when fast fix is engaged is metal, not plastic. Mine still broke once and I had to replace it.

 

[squall_line]

If you need assistance finding the brushes to check them...
https://www.festoolownersgroup.com/ask-festool/kapex-brushes/