Replacing the Armature in a TS-55

[Sinorm]

Yesterday I was cutting through some plywood and smoke started pouring out of my TS-55. After disassembling the tool, it was obvious that the armature was ruined (and from searching these message boards, it is clear that this is a common failure). Unfortunately my warranty ran out a few months ago so I ordered the parts instead of sending the tool in for repair.

I've successfully exposed the armature, but I can't figure out how to remove it from the tool so I can install the replacement. There aren't any fasteners that I can see, so I'm assuming the armature is press-fit into the housing? It seems like I'll have to press it back out somehow, pushing from the blade side of the saw on the small exposed end of the armature shaft.

Has anyone replaced their armature before? Any recommended techniques or is there something I'm missing?

 

[peter halle]

Sorry for your situation.  You should contact FESTOOL about this.

RegArding your comment about reading that an armature failure in a TS 55 is common failure I can only offer that perhaps you might have gotten tools mistaken and were thinking about the Kapex. 

Peter

 

[antss]

You need to separate the armature / fan from the housing and then use a bearing puller (probably) to remove the fan. 

I'd go ahead and replace the bearings while you're in there too.  Cheap insurance.

You may want to give FT a call on Monday and talk to service.  I'll bet you a dollar or a donut that they'll talk you through the procedure.  I had to replace something minor on an old AT saw 15 years ago and couldn't figure it out so I called and they pointed me in the right direction.  It required a particular sized brass drift in a position I just didn't see.

 

[Sinorm]

I was able to complete the repair and my saw is up and running again. I ensured the back of the gearbox was well-supported and then used a hammer and punch on the end of the armature shaft to remove the armature. It took some fairly serious hammering, but I was able to get it removed without any damage. After you've removed the shaft the fan slides right off, no bearing puller needed.

Installation of the new armature was easy enough. I did replace the end bearing so I just hammered the new bearing onto the shaft instead of trying to remove the old bearing. Then I ensured the blade-side of the housing was well-supported and proceeded to hammer away on the new armature until it was fully seated in the bearing. Then I just had to reassemble the saw and get back to cutting.

 

[antss]

Glad to hear you sorted it.

Nothing beats the feeling of pounding on your $500 saw with a big ol hammer and a drift.  [scared] [scared] [scared] 

 

[Birdhunter]

I admire your ability to fix the problem, but why not ship the saw to Festool?

 

[antss]

I admire your ability to fix the problem, but why not ship the saw to Festool?

"Unfortunately my warranty ran out a few months ago "

Shipping both ways likely to run $50-$60 alone plus insurance, plus parts min. $125, plus labor and one is looking at a pretty sizable investment on a $300-$400 saw.

 

[AlexThePalex]

I admire your ability to fix the problem, but why not ship the saw to Festool?

If you're comfortable doing your own repairs, why waste a lot of money on shipping and labour?

 

[mwahaha]

You could have probably used a heat gun to heat the alloy and the bearing would have come out a lot easier. The same trick is used to get pressed in  bearings out of alloy bike hubs.