FESTOOL DOMINO DF 500 Q Jointing Machine Instruction Manual

FESTOOL DOMINO DF 500 Q Jointing Machine Instruction Manual

FESTOOL DOMINO DF 500 Q Jointing Machine

1 Introduction

Thank you very much for purchasing the Domino
Dowel Jointer DF 500 Q from Festool.  Please observe the information in these Operating Instructions and the enclosed documents.
They are for your own safety and to help prevent damage to the machine.

2 Technical data

Power                                                  420 W

Speed (no load)                              25 500 rpm
Jointing depth, max.                              28 mm
Jointing width, max.              23 mm + jointer bit
diameter
Jointing bit diameter, max.                     10 mm
Connecting thread of drive shaft           M6 x 0.75
Weight (excluding cable)                          3.2 kg
Degree of protection                                   / II

3 Pictograms

4 Intended use

The Domino dowel jointer is designed to produce
Domino dowelled joints in soft and hard wood, chip board, plywood and fi bre boards. All applications beyond this are regarded as unspecifi ed use.
The Domino dowel jointer is designed and approved for use by trained persons or specialists.

The user is liable for damage and injury resulting from incorrect usage!

5 Safety instructions

5.1 General Safety Rules

WARNING! Read all safety warnings and all instructions.
Failure to follow the warnings and instructions may result in electric shock, fi re and/or serious injury.
Save all warnings and instructions for future reference.
The term „power tool“ in the warnings refers to your mains-operated (corded) power tool or battery-operated (cordless) power tool.

5.2 Tool-specific safety rules

• Hold power tool by insulated gripping surfaces, because the cutter may contact its own Cutting a ”live” wire may make exposed metal parts of the power tool “”live”” and could give the operator an electric shock.
• The tools must be designed for the speed specified on the power tool at a minimum. Tools running at overspeeds can fly apart and cause
• Use the machine only with the guide frame The guide frame protects the user against broken-off parts of the jointer bit and accidental contact with the jointer bit.
• The DF 500 Q must only be fitted with the jointer bits offered by Festool for this purpose. The use of other jointer bits is prohibited due to the increased risk of
• Never work with blunt or damaged jointer Blunt or damaged jointer bits can lead to a loss of control of the power tool.

When the motor unit is released, it must move back actuated by spring force so that the jointer bit disappears completely in the protective cover. If this does not happen, the machine must be switched off immediately and repaired before reuse.
To protect your health, wear a P2 protec- tive mask.

5.3 Noise and vibration information

The typical values determined in accordance with
EN 60745 are:
Sound-pressure level 84 dB(A)
Sound-power level 95 dB(A)
Measuring uncertainty allowance K = 3 dB

Wear ear protection!

Vibration emission value ah (vector sum for three directions) and uncertainty K measured in accordance with EN 60745:
Vibration emission value ah = 3,0 m/s² K = 1,5 m/s²

The emission values specified (vibration, noise) were measured in accordance with the test con- ditions stipulated in EN 60745 and are intended for machine comparisons. They are also used for making preliminary estimates regarding vibration and noise loads during operation. The emission values specified refer to the main applications for which the power tool is used. If the electric power tool is used for other applications, with other tools or is not maintained sufficiently prior to opera- tion, however, the vibration and noise load may be higher when the tool is used. Take into account any machine idling times and downtimes to estimate these values more accurately for a specified time period. This may significantly reduce the load dur- ing the machine operating period.

6 Control elements

(1.1) ON/OFF switch
(1.2) Rotary switch for Domino dowel-hole width
(1.3) Unlocking device for motor unit / guide frame
(1.4) Auxiliary handle
(1.5) Clamping lever for angle guide
(1.6) Selection slide for material thickness
(1.7) Notch lever for Domino dowel-hole depth
(1.8) Notch lever lock
(2.1) Spindle lock
(2.2) Extraction nozzle
(2.3) Clamping lever for jointing height adjustment
(2.4) Stop latch

7 Power supply and start-up

The mains voltage must correspond to the specifi cation on the rating plate.
Always switch the machine off before connecting or disconnecting the mains lead!

See Fig. 2 for connection and disconnection of the power cable.
To switch on, push the switch (1.1) forwards until it engages. Pressing the back end of the switch is suffi cient to release the switch-on lock and switch the machine off.

8 Machine settings

Always remove the power supply plug from the socket before carrying out any work on the machine.

8.1 Changing tools

Required tools: fork wrench a/f 8 (supplied).
Always wear protective gloves during tool change due to the risk of injury from the sharp tool cutters.

a) Removing the tool

– Lift the unlocking lever (4.2) until it audibly engages with the fork wrench (4.1).
– Separate the motor unit (4.5) and the guide frame (4.4).
– Press and hold in the spindle lock (5.1).
– Release and unscrew the jointer bit (5.2) with the fork wrench.
– Release the spindle lock.

b) Inserting the tool

– Before inserting a new jointer bit, ensure that the machine, the guide frame and the guides
(4.3) are clean. Remove any contamination that may be present. Only use sharp, undamaged and clean tools.
– Press and hold in the spindle lock (5.1).
– Use the fork wrench to screw on the jointer bit(5.2).
– Release the spindle lock.
– Slide the guide frame onto the motor unit until it audibly engages.

8.2 Adjusting the milling depth

– Open the notch lever lock (1.8) by pressing it.
– Use the locking lever (1.7) to set the desired jointing depth (12 mm, 15 mm, 20 mm, 25 mm, 28 mm). For the jointer bit with a diameter of 5 mm, only jointing depths of 12 mm, 15 mm and
20 mm are permitted due to its short shank length.
– Release the notch lever lock again. A special cutter is available for the DOMINO dowel 4×20 mm (due to risk of breakage). Note the following when using this cutter (D 4-NL 11 HW-DF 500):
– Set the routing depth to 20 mm using the stop lever (1.7). The actual routing depth is 10 mm.

The dowel can only be positioned centrally (see Fig. 7b).
Ensure that the jointing depth is at least 3 mm smaller than the workpiece thickness. Otherwise the jointer bit can emerge from the workpiece at the rear side, which involves an increased risk of injury.

8.3 Setting jointing height a) with selection slide

– Release the clamping lever (6.1) for jointing height adjustment.
– Using the additional handle (6.2), raise the front section of the guide frame.
– Use the slide (6.6) to set the desired board thickness (16 mm, 20 mm, 22 mm, 25 mm, 28 mm, 36 mm, 40 mm).
– Press the front section of the guide frame downwards as far as the stop.
– Close the clamping lever (6.1).

b) freely selectable

– Release the clamping lever (6.1) for jointing height adjustment.
– Using the additional handle (6.2), raise the front section of the guide frame.
– Push the slide (6.6) to the stop in direction motor unit.
– Set the desired jointing height using the scale (6.3) by moving the front section of the guide frame vertically.
– Close the clamping lever (6.1).

8.4 Setting angle guide

– Release the clamping lever for the angle guide (6.4).
– Set the desired angle: using the scale (6.5) steplessly from 0° – 90°, or in notches at 0°, 22.5°, 45°, 67.5°, 90°.
– Close the clamping lever (6.4).

Mitre cutting thin workpieces

– Set the desired angle.
– Release the clamping lever (6.1) for jointing height adjustment.
– Push the slide (6.6) to the stop in direction motor unit.
– Slide the angle stop all the way down.
– Close the clamping lever (6.1).

Always release the clamp lever (6.1) before resetting the angle stop.

8.5 Setting dowel-hole width

Reliable setting of the dowel-hole width with the rotary switch (1.2) is only possiblem with the machine running!

The following dowel-hole settings are possible
(image 7a):
13 mm + jointer bit diameter
19 mm + jointer bit diameter
23 mm + jointer bit diameter

8.6 Dust extraction

Always connect the machine to a dust extractor. You can connect a Festool extractor with an extractor hose diameter of
27 mm to the extractor connector (2.2).

8.7 Side stop with extension

The side stop (8.1) can be used to enlarge the contact surface when jointing on the workpiece edge, thus allowing safer guidance of the machine.
The distance to the centre of the routed hole can be reduced from 37 mm to 20 mm using the two integral stop spacers (8.6), allowing you to position the dowel closer to the edge.
– Secure the side stop to the threaded bores (8.3) on the guide frame using both screws (8.2), whereby the contact areas of the support ring
(8.5) and the table (8.4) must be level with one another.
– Swivel one of the distance spacers (8.6) outwards to reduce the distance (see Fig. 8). The spacer aligns automatically with the stop latch (8.7).

9 . Working with the machine

Wood is a natural, non-homogenous material and because of this, its dimensions will most likely deviate slightly during processing, even if the machine is set accurately. Machine handling also influence the degree of working accuracy (e.g. fast-feed speed). Furthermore, the dimensions of wooden DOMINOs may vary (for example, due to humidity), regardless of how they are stored. All of these factors influence the dimensional accuracy of manufactured dowel holes and dow- elling joints.

Numerous tests have been run to produce an average figure for these dimensional discrepan- cies. The dimensions of the machine and DOMINO dowels are based on these averages. If a lateral offset of approx. 0.03 mm – 0.04 mm occurs when two workpieces are joined together, you have the option of replacing the stop latches (2.4) fitted on delivery with correction stop latches. These latches are 0.15 mm narrower and reduce the lateral clearance of the dowel holes in relation the edge of the workpiece (see Chapter 14).
Prior to processing the final workpiece, it is advis- able to optimise the dowel-hole depth, width and diameter using a sample workpiece.

Please observe the following rules when working:

Please observe the following rules when working:

• Always secure the workpiece in such a manner that it cannot move while being
• Always hold the Domino dowel jointer with both hands at the motor housing and at the additional This reduces the risk of injury and is a prerequisite for precise work.
• Close the clamping lever for jointing height adjustment (2.3) and the clamping lever for the angle guide (1.5) so that accidental release dur- ing operation is
• Adapt the feed rate to the jointer bit diameter and Work with a constant feed rate.
• Only lay the Domino dowel jointer aside when the jointer bit has come to a complete

Procedure

Proceed as follows to create a dowelled joint:

• Select a Domino dowel and insert a matching jointing bit in the Domino dowel jointer (Chap. 1).
• Set the jointing depth (Chap. 8.2). The jointing depth must be at least 3 mm smaller than the workpiece thickness so that the dowelled joint is
• Set the jointing height to correspond to the workpiece thickness (Chap. 3).
• Mark the areas on the workpiece that belong together (10.1) so that you will be able to join them correctly again once you have cut the dowel
• Position the two workpieces to be joined against one another and mark the desired positions of the dowels with a pencil (10.2).
• Set the desired dowel-hole width (Chap. 5). Our recommendation: Cut the first hole without play (dowel-hole width = Domino dowel width), and the remaining dowel holes to the next largest dowel-hole width (image 10). The first dowel hole therefore serves as a reference dimension, whereas the remaining dowel holes have toler- ance for manufacturing inaccuracies.
• Cut the dowel holes:

1. the first dowel hole by placing the stop latch at the side edge of the workpiece,
2. the following dowel holes according to the pencil markings made beforehand and the scale of the viewing window (10.3).

10 **Maintenance and care**

Always remove the power supply plug from the socket before carrying out any work on the machine.
All maintenance and repair work which requires the motor casing to be opened may only be carried out by an authorised service centre.
The Domino dowel jointer is to a large extent maintenance-free. However, we recommend an annual inspection and/or a check after approx. 100 operating hours at an authorised customer service workshop. This is for the safety of the user and the value stability of the Domino dowel jointer.
Always keep the machine and the ventilation slots clean.
Dust deposits must be removed from the guides (4.3). Oil the guides regularly and lightly with resin-free oil (e.g. sewing machine oil).

To secure the clamp lever (see Fig. 6b):

• Remove the clamp lever and tighten the hexagon
• Attach the clamp lever to the hexagon screw

The tool is fitted with special motor brushes with an automatic cut-out. When the brushes become worn the power supply is shut off automatically and the tool comes to a standstill.

11 Accessories, tools

For your own safety, use only original Festool accessories and spare parts.
The accessory and tool order number can be found in the Festool catalogue or on the Internet under “www.festool.com”.

12 Disposal

Do not throw the power tool in your household waste! Dispose of the machine, accessories and packaging at an environmentally-responsible recycling centre! Observe the valid national regulations. EU only: European Directive 2002/96/EC stipulate that used electric power tools must be collected separately and disposed of at an environmentally responsible recycling centre.

13 Warranty

Our equipment is under warranty for at least 12 months with regard to material or production faults in accordance with national legislation. In the EU countries, the warranty period is 24 months (an invoice or delivery note is required as proof of purchase). Damage resulting from, in particular, normal wear and tear, o-verloading, improper handling, or caused by the user or other damage caused by not following the oper

ating instructions, or any fault acknowledged at the time of purchase, is not covered by the war- ranty. Complaints will only be acknowledged if the equipment has not been dismantled before being sent back to the suppliers or to an author- ised Festool customer support workshop. Store the operating instructions, safety notes, spare parts list and proof of purchase in a safe place. In addition, the manufacturer’s current warranty conditions apply.

Note

We reserve the right to make changes to the tech- nical data contained in this information as a result of ongoing research and development work.

14 EC-Declaration of Conformity

Dowel jointer Serial no.
DF 500 Q 498621, 498622
Year of CE mark: 2006

We declare at our sole responsibility that this product is in conformity with the following standards or standardised documents: EN 60745-1,
EN 60745-2-19, EN 55014-1, EN 55014-2, EN

61000-3-2, EN 61000-3-3 in accordance with the regulations 2006/42/EC, 2004/108/EC.
Dr. Johannes Steimel 06.12.2010 Head of Research, Development and Technical Documentation

Festool GmbH
Wertstrasse 20 73240 Wendlingen, Germany

REACH for Festool products, their accessories and consumables

REACh is a European Chemical Directive that came into effect in 2007. As “downstream users” and product manufacturers, we are aware of our duty to provide our customers with information. We have set up the following website to keep you updated with all the latest news and provide you with information on all the materials used in our existing products: www.festool.com/reach

15 Example applications

(The following images A1 to A6.3 are on a separate enclosed sheet).

construction.
A4.1 – A4.3| Stable, non-twisting and precisely fitting board joint (mitred).
A5.1| Stable and precisely fitting board joint (butted).
A5.2| Setting the Domino dowel jointer for board joint (butted), end face dowel hole.
A5.3| Setting the Domino dowel jointer with angle bracket for board joint (butted).
A6.1| Stable and precisely fitting board joint (centred).
A6.2| Setting the Domino dowel jointer for board joint (centred).
A6.3| Setting the Domino dowel jointer for board joint (centred), end face dowel hole.

16 Fault correction

(The following images B1 to B6 are on a separate enclosed sheet).

deposits (e.g. chips) below the base plate

b)  angle guide not set exactly to 90°

c)  worked on without angle bracket

| a)    remove deposits

b)   set angle guide to 90° exactly

c)    use angle bracket

9a, 9b| The position of the dowel holes, which were created with the left and right stop latch, does not exactly match (different distance to workpiece edge).| The midpoint between the two stop latch is not exactly in the midpoint of the swivel range of the jointer bit.| Remove one of the stop latches (9.1) (Fig. 9a). Attach one of

the accompanying stop latches (9.2) to the dowel jointer (Fig. 9b).These stop latches are nar- rower and allow you to make more accurate adjustments.

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References

• Responsibility for the environment at Festool
• Festool Worldwide - Tools for the toughest demands
• Festool Worldwide - Tools for the toughest demands

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