Need guidance...Domino 500 stopped working - SOLVED

[elm]

I love my domino 500; don't know how I did without one for so long.  I am just a hobbyist but it has really come in handy.  I recently took it on a trip with me to make some cabinets, etc. for my mother.  During the preparation of a bathroom vanity base it 'stalled out'.  It was like there was no power going to it.  I turned it off and back on and all was good.  Then it continued to repeat this pattern.  Sometimes it did not turn on.  I tapped it a few times and it started up but a various speeds.  I then turned it on and off several times and got it to go for one or two cuts and then off it went.  I eventually found that as it was 'stalling out' if I pressed it deeper into the cut it kind of jump started it...it was like it needed that shaking to keep it going. It did not last long, but allowed me to get what I needed done.  When I say that it literally died (and will not turn on) on my last cut.  I also tried different power cords.  Did not make a difference.  I was also not using an extension cord.

It is one of the older models with metal alignment pins and I got it second hand from a cabinet maker who was retiring.  It has done well until now.  Reading through the threads it seems it might be the armature, but I don't know.  I can of course send it in for repair, but it will be out of warranty and possibly expensive.  I do not mind fixing it myself if I was reasonably certain what I needed to replace. 

Any advice on this one?  Seen something similar and know what fixed it?  Any assistance is much appreciated.

 

[peter halle]

First thing I would advise is to disconnect the cord and look at the pins on the tool.  Are they dark or shiny?  If dark you might have had an issue with the plug it connector.  If you have multiple cords you must have multiple tools.  Check them all and the cords also to look for dark or burned connectors.  Make sure that you have the plug it cord fully locked before using a tool.

just a thought.

Peter

 

[elm]

Thanks Peter.  Tried that.  Used multiple cords and none made a difference.  The Plug It cords worked on the other tools.  Also physically moving the cord around (pressing it in different angles to ensure contact) did not restore power.  It was fully locked every time.

 

[peter halle]

If the pins on the tool end of the connection are burnt then other cords won't help you.  Maybe I misunderstood you (an if so I apologize) but the pins cause the issues usually and then it transfers to the sockets (cords) and then those can cause damage to other tool pins faster than a kid with a cold in daycare.  That is why I wanted you to check the pins and sockets.  If there is an issue I didn't want it to spread.

Peter

 

[RKA]

It's like a Festool STD.  But he's right, check the tool end pins and if you see a problem, quarantine any cord that was used with that Domino recently.

Your issue does sound eerily like an electrical issue.  I would try replacing the switch since you mentioned you were able to get it going by cycling the switch on and off or by tapping the unit (which may have been enough to restore a failing connection).  But ultimately a poor electrical connection will get worse and fail completely.

 

[elm]

Peter,
Thanks. I missed the important part of your original posting to look at the tool pins. Just did...shiny as new.

RKA,
That would be a great (cheap) fix. I will investigate that as well.

 

[NL-mikkla]

Sure sounds like a failing connection if tapping can turn it back on.
If not the pins and cable, open it up and check all there is to check.
If you can find it, send it in for repair, get a quote first, doesn’t sound like an expensive repair.

 

[Gregor]

I had similar with my DF 700 (after

 

[jimbo51]

"doesn’t sound like an expensive repair"

If it is just the switch, yes. However, with all the electronics in tools these days, there could be a failed $5 component on a $100 assembly and they replace the whole assembly.  Festool also may want to replace other somewhat worn bits and pieces. After adding in labor costs, the repair might become expensive.

Please let us know the final outcome.

 

[elm]

Well I just wrote a fairly lengthy reply to all here with the solution.  It included pics, so maybe it takes some time to post.  I am not sure I have it in me right now to repeat that reply and will see if it does post but in the interim here is the brief version.

After taking several pieces off I found that I only needed to remove the back screw next to the Plug it connector.  That exposes the Plug it piece which is actually the switch as well.  A long arm pushes it on when you slide the external green switch.  I followed the wires and found loose connections on both sides of the armature.  I pinched then ever so slightly and slid them back on for a tight fit.  The Domino fired right up.  I will not know if this is the actual solution until I test it under load for a bit, but I will do that hopefully this weekend.  If it is not the fix, I will report back.

I really appreciate everyones input and fast replies.  This was my first post on FOG and you guys really helped me out.  Everyone gets credit for this solution.  Hopefully it is the permanent fix and did not cost me a dime.  Again thanks everyone so much.  I will keep looking for my other post which includes pics of the switch and some other details.

 

[Birdhunter]

I’m happy for you that the Domino is running again. Please endeavor to post pictures of the repair sequence.

 

[elm]

Okay...I do not see the previous post with pics that I put up so here is a bit more detail.  I just tried to post again and it did not work, so I will try the text and then the pics.

I must first start out by saying when I did the fix I put the Domino on my kitchen table and my wife looked over and said "Do I need to move some things on the table so you have more room?".  I have always known I married the right woman, but this was one of my daily reminders that I did.

I initially was going to get the switch out and armature and test both.  I figured the switch was under the external green switch and I had no idea how I was going to get to the armature.  I removed all of the screws you can see on the external body (holding on the plastic parts).  It turns out the back screw (next to the Plug it connector) is the only one you need to remove for the switch.  For the armature, I could see it but could not find a way to remove the main covering (got it loose, but it was obviously still attached somewhere).  I found what looked like a connector when the actual switch was removed, but did not try it since, as previously posted, I found some loose connections that seemed to have fixed the problem.

To remove the switch, remove the one screw on the back near the Plug it connector.  The back end then pulls off.  There are two screws to remove and then two tabs on each side of the Plug it connector assembly.  Remove the screws and pinch the tabs together gently and pull up. The assembly will come out. The actual switch is on the bottom of that assembly (white pice on the pic).  When the external green switch is slide into place, it moves a long arm that has a 'ramp' to it that pushes the switch to the "on" position.

The other end of the switch is connected to the armature via standard spade connectors.  Remove those and put on your new switch.  In my case the connectors were loose at the armature so I got a pair of needle nose pliers and gently pressed the connector closed (ever so slightly) and then pushed it back on for a snug fit.  After doing this the Domino fired right up.

I did not include a pic of the screw on the back of the Domino (you can look at yours...it is obvious).  But I did include a picture of the switch along with the part number.  Perhaps you will find it useful.  The wires on each side are the ones going to the armature and mine were loose at the connection to the armature.

I will post if this does not fix it under actual load.  Hopefully this helps others.  As stated earlier, this was my first post on FOG and everyone was very helpful.  Lots of quick and relevant advice.  It was of great value to me.  Thanks everyone.

[attachimg=1]

 

[elm]

pic 1

 

[elm]

loose connections

 

[elm]

switch - upside down though

 

[elm]

Well not a lot of use, but I have built 6 cabinet doors with the Domino and not a peep of a problem (I hope I did not just jinx myself).  In fact it is running quite well.  I noticed some 'less than clean' cuts before so I suspect it was getting intermittent power for most of my last job.  But now it is back to nice and clean and reliable.  Thanks again all for your advice.  Turned out to be a simple fix.  If your's is not in warranty and you are having a similar issue, I suggest you pop off the back cover and ensure you have a good connection.  If I had to do it again, it would take less than 5 min.

 

[RKA]

Glad it was a cheap and easy fix!  Thanks for sharing the pics and solution, I’m sure it will be helpful to others!

 

[otskarl]

This is a superb post!
Got a new def-500 out of the box. Worked for 0,5 seconds and then stopped. I was sure that this was a simple error. Quick google showed me this post and what do you know - visibly there were no loose connections, but just to be sure I wiggled them and now works like a charm!

Thank you

 

[Bob D.]

"Well I just wrote a fairly lengthy reply to all here with the solution.  It included pics, so maybe it takes some time to post.  I am not sure I have it in me right now to repeat that reply and will see if it does post but in the interim here is the brief version."

BTDT and cursed myself every time it happens. Invariably the problem is me, I forget to reduce the image file size. MS Image Resizer makes this very easy but you have to remember to use it or resize in your image editor of choice before uploading. 

Now I try to remember to save a post before I add photos and resize so the images are