Rotex 150 - broken gears or shaft

[mikew151]

Hi all

Today i was sanding 40grit hard on rotex mode and i think something gear or shaft related broke inside. I took the pad off and then removed the counter balance, the ball bearing and the bear housing

This took me to the the eccentric disk (the thing that has fan blades) this seems to be scraping on the side of the casing when turned - this is clear because there are grind marks on one side.  it's really hard to turn and when its forced to turn there is a horrible "clacking" sound.

could this be a bent shaft??

if so how do i get to the shaft / and remove the gear that's blocking it??

Please HELP! any thoughts will be much appreciated....

cheers guys

 

[AlexThePalex]

That sounds like some serious damage, how did that happen?

I can only offer two pieces of advice:

1 - Contact Festool service department, and send it in for repair.

2 - On the menu bar of this forum you'll see Additional Websites, go to Spare Parts Catalog to find your Rotex with an exploded view diagram and a parts list you can order.

Good luck.

 

[mikew151]

ok so, I identified the issue.

I managed to remove the clam shell (second bit with a pry and wiggle), bearing, counter blance, bearing housing.

It then came to the gear which previously troubled me but i worked out that I needed to remove the green gear switch at the top. this then revealed a hex bolt which unscrewed. gave that a couple of hits with a screwdriver and the shaft and gear popped out.

removed the 4 housing screws and then tapped with a small hammer around the lip of the housing and the eccentric disc popped out.

OH MY GOD!!! the pinion and armature gear were totally mangled - that explains the clacking sounds.

considering a new armature (comes with the pinion and gear) is £160 part and the machine is a 2007 model - its safe to say, it's a total right off and will be ebaying it for spares....

I hope this helps someone else

 

[xedos]

I wouldn't be so quick to toss the thing.   

160 quid to repair a sander that costs 660 pounds new,  doesn't seem like a bad value proposition to me.  Even adding new set of brushes and bearings and you're still only into it for around two hundred.

I guess you could go for the new Bosch GET sander for 250ish which would be pretty close to the repair cost of the RO.

 

[bresg]

ok so, I identified the issue.

I managed to remove the clam shell (second bit with a pry and wiggle), bearing, counter blance, bearing housing.

It then came to the gear which previously troubled me but i worked out that I needed to remove the green gear switch at the top. this then revealed a hex bolt which unscrewed. gave that a couple of hits with a screwdriver and the shaft and gear popped out.

removed the 4 housing screws and then tapped with a small hammer around the lip of the housing and the eccentric disc popped out.

OH MY GOD!!! the pinion and armature gear were totally mangled - that explains the clacking sounds.

considering a new armature (comes with the pinion and gear) is £160 part and the machine is a 2007 model - its safe to say, it's a total right off and will be ebaying it for spares....

I hope this helps someone else

Hello,
thanks for the reply and sorry to dig up this thread.
I have already a problem on the gear on my rotex 150 and I'd like to know how you removed the "inner" gear part, the one which is drived by the motor.
Could you give me some advices?
Best regards,
bresg