Kapex sticks when depressed to cut

[MrGinCT]

In the past week week my Kapex has become difficult to depress to make a cut and is getting quite difficult to use without applying a lot of force to move the saw head downward.  I've tried lubricating it but no significant improvement.  Suggestions?

 

[semenza]

If you haven't already done so .................. start by making sure the head lock pin is pulled all the way out and make sure the trench setting lever is completely disengaged.

Seth

 

[MrGinCT]

I have and have double checked myself a number of times

 

[tjbnwi]

https://www.festoolownersgroup.com/...hard-to-start-the-plunge/msg614641/#msg614641

Tom

 

[jefL]

I had a similar problem on my KS120 but none of the fixes in the various threads fixed it so I took the thing apart to see [unsure] what was wrong. It was the trigger bar (78) not pushing the interlock lever (35) to the guard far enough and not allowing the guard to move, locking the saw up.

[attachimg=1]

The problem was the moulded pin on 35 was a loose fit in the hole in 78, indicated by the red line. A quick fix was to wrap the pin in a turn or two of insulation tape to take up the slop in the hole. Worked a treat, just wait now to see how long it lasts. Next time I'll have to engineer a better solution, or buy new parts.
The pin wasn't worn but maybe the hole was, the plastic is quite thin.

Jef

 

[ChuckM]

Jef, I can't but wonder what profession you are or were in. Your clear explanation of the problem and solution as aided by the diagram is a professional job. I wish others, especially those who have a technical woodworking problem, would try to follow your example when they present their questions (or suggestions).

 

[jefL]

I'm retired now but spent 42 years as an electrical engineer in the UK electricity supply industry working
on high voltage equipment and protection systems up to 132,000volts. Clear communications are vital in a safety critical environment like that.
I'd never have let my guys get away with an insulating tape repair like that either  [big grin]
I'm going to have to either come up with a better repair or buy a new part 78 in the near future, it's nagging at me.

Jef

 

[ChuckM]

Jef, The solution should have come from the Festool designers if they knew that high traffic spot was subject to premature wear. Other more durable material might have been used instead of plastic for that contact point perhaps?