DF 500 QPlus - Electric router FESTOOL - Free user manual and instructions

Product type	Domino tenon router bit
Rated power	420 W
No-load speed	25,500 rpm
Max. routing depth	28 mm
Max. routing width	23 mm + ∅ of router bit
Max. router bit diameter	10 mm
Thread of drive shaft	M6 x 0.75
Weight (without cable)	3.2 kg
Protection class	II
Sound pressure level	84 dB(A)
Sound power level	95 dB(A)
Vibration emission (ah)	3.0 m/s² (K=1.5 m/s²)
Depth settings	12, 15, 20, 25, 28 mm (by lever)
Router bit height adjustment	By slide plate thickness 16-40 mm or continuous vernier
Angular stop	0° to 90° with detents at 0°, 22.5°, 45°, 67.5°, 90°
Dust extraction connection	Diameter 27 mm
Machinable materials	Soft and hard woods, particle boards, plywood, fiber boards
Maintenance of guides	Light resin-free oil (e.g., sewing machine oil)
Supplied accessories	Open-end wrench 8, stop extension, stop reducers
Safety	Column block, spindle lock, automatic brush cut-off

Frequently Asked Questions - DF 500 QPlus FESTOOL

How to change the router bit on the Festool DF 500 QPlus?

Unlock the motor block by lifting the lever [4-2] until it engages. Press the spindle lock [5-1] and unscrew the router bit with the supplied open-end wrench. To mount, screw on the new router bit while holding the spindle lock, then raise the column block until it engages.

What routing depths are available?

The preset depths are 12, 15, 20, 25 and 28 mm, selectable via the locking lever [1-7]. For 5 mm router bits, only 12, 15 and 20 mm are allowed.

How to adjust the routing angle?

Loosen the angular stop locking lever [6-4], set the desired angle (continuous 0-90° or detents at 0°, 22.5°, 45°, 67.5°, 90°) and retighten the lever.

Can I use non-Festool router bits?

No. Only router bits supplied by Festool are authorized for the DF 500 Q model, as using other bits poses a high risk of injury.

How to connect a vacuum cleaner?

The machine has a dust extraction connection [2-2] that accepts a 27 mm hose. Connect a Festool or compatible vacuum for dust extraction.

What safety instructions are important?

Always wear safety glasses, hearing protection and a P2 mask. Only use the machine with the column block mounted. Check that the router bit fully retracts into the cover at startup. Unplug the machine before any intervention.

How to maintain the machine?

Regularly clean the guides [4-3] and lightly oil them with a resin-free oil. Have the machine checked every year or every 100 hours by a Festool authorized workshop.

What to do if the mortises are not parallel?

Check that the workpiece is securely fixed. If the problem persists, the stop catches can be replaced with correction catches (finer) to reduce lateral deviation.

What accessories are included with the DF 500 QPlus?

The unit is supplied with an open-end wrench size 8, a stop extension with two integrated reducers, and additional stop catches. Consult the Festool catalog for optional accessories.

How to resolve burn marks on the wood?

Burn marks are usually caused by a dull router bit. Replace it with a sharpened bit. Also ensure that the feed speed is not too slow.

USER MANUAL DF 500 QPlus FESTOOL

GB Original operating manual - Dowel jointer 12

Exterior view of a black-and-white industrial power saw with coiled cable (no visible text or symbols)

1-11-21-31-4 DOMINO 1-8 1-7 1-6 1-5 1

2 2-1 2-2 2-3 2-4 2

Technical diagram illustrating cable connector assembly steps with numbered instructions and directional arrows

4-3 4-2 4-1 DOMINO 12 15 20 25 28 4-5 4-4

5-1 5-2

10-3

Wolfgang Zondler
Head of Research, Development and Technical Documentation

Wendlingen, 2016-12-14

Declaration of Conformity

We as the manufacturer Festool GmbH, Wertstraße 20, 73240 Wendlingen, Germany declare under our sole responsibility that the product(s):

Designation:

Designation of Type(s):

Serial number(s) ^1) :

Joining machine

DF 500 Q

498621, 498622

fulfills all the relevant provisions of the following UK Regulations:

S.I. 2008/1597
S.I. 2016/1091
S.I. 2012/3032
Supply of Machinery (Safety) Regulations 2008
Electromagnetic Compatibility Regulations 2016
Restriction of the Use of Certain Hazardous Substances in Electrical and Electronic Equipment Regulations 2012

and are manufactured in accordance with the following designated standards:

• BS EN 60745-1:2009 + A11:2010
• BS EN 60745-2-19:2009 + A1:2010
• BS EN 55014-1:2017
• BS EN 55014-2:2015
• BS EN IEC 61000-3-2:2019
• BS EN 61000-3-3:2013
• BS EN IEC 63000:2018

1) in the specified serial number range (S-Nr.) from 400000000 - 499999999

Place and date of declaration: Wendlingen, 03.05.2021

Signed on behalf of and in name of Festool GmbH

Markus Stark Head of Productdevelopment

i.V.Q.Bordt

Ralf Brandt

Head of Productconformity

D

Dowel jointer Table of contents

1 Machine features 12
2 Technical data 12
3 Pictograms....12
4 Intended use 12
5 Safety instructions....12
6 Power supply and start-up 13
7 Machine settings....13
8 Working with the machine....14
9 Maintenance and care 15
10 Accessories, tools.... 15
11 Environment....15
12 Example applications.... 16
13 Fault correction 16

1 Machine features

[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

The specified illustrations can be found at the beginning of the operating instructions.

2 Technical data

Power 420 W

Speed (no load) 25 500 min

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

, Danger!

r ear protection!

Wear protective goggles!

Manual, read the instructions.

r a protective mask!

CE marking: Confirms the conformity of the power tool with the European Community directives.

UKCA marking: The United Kingdom Conformity Assessed symbol is a marking for products being placed on the market in the United Kingdom. It is a manufacturers indication that the product is in conformance with the relevant regulations in the UK.

4 Intended use

The Domino dowel jointer is designed to produce Domino dowelled joints in soft and hard wood, chip board, plywood and fibre boards. All applications beyond this are regarded as unspecified 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, fire 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

• Mounting tools must be rated for at least the speed marked on the tool. Mounting tools running over rated speed can fly apart and cause injury.
• Always use the guard. The guard protects the operator from broken mounting tool fragments and unintentional contact with the mounting tool.
• Hold power tool by insulated gripping surfaces, because the cutter may contact its own cord. Cutting a "live" wire may make exposed metal parts of the power tool "live" and could give the operator an electric shock.
• 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 injury.

• Never work with blunt or damaged jointer bits. 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.
• Only for AS/NZS: The tool shall always be supplied via residual current device with a rated residual current of 30 mA or less.

To protect your health, wear a P2 protective 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

r ear protection!

Vibration emission value a_h (vector sum for three directions) and uncertainty K measured in accordance with EN 60745:

Vibration emission value a _h = 3,0 m/s^2 K = 1,5 m/s²

The specified emissions values (vibration, noise) – are used to compare machines.
- They are also used for making preliminary estimates regarding vibration and noise loads during operation.
- They represent the primary applications of the power tool.

Increase possible for other applications, with other insertion tools or if not maintained adequately. Take note of idling and downtimes of machine!

6 Power supply and start up

The mains voltage must correspond to the specification 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 sufficient to release the switch-on lock and switch the machine off.

7 Machine settings

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

7.1 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.

7.2 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 4x20 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.

7.3 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].

7.4 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.

7.5 Setting dowel hole width

Reliable setting of the dowel-hole width with the rotary switch [1 2] is only possible with the machine running! The following dowel-hole settings are possible (Fig. 7a):

13 mm + jointer bit diameter
19 mm + jointer bit diameter
23 mm + jointer bit diameter

7.6 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].

7.7 Additional stop with extension

The additional 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 additional 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].

8 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 dowelling joints. Numerous tests have been run to produce an average figure for these dimensional discrepancies. 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 advisable to optimise the dowel-hole depth, width and diameter using a sample workpiece.

se observe the following rules when working:

• Always secure the workpiece in such a manner that it cannot move while being sawed.
• Always hold the Domino dowel jointer with both hands at the motor housing and at the additional handle. 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 during operation is impossible.
• Adapt the feed rate to the jointer bit diameter and material. Work with a constant feed rate.
• Only lay the Domino dowel jointer aside when the jointer bit has come to a complete standstill.
• Use the machine only with the guide frame mounted.

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. 7.1).
• Set the jointing depth (Chap. 7.2). The jointing depth must be at least 3 mm smaller than the workpiece thickness so that the dowelled joint is supportable.
• Set the jointing height to correspond to the workpiece thickness (Chap. 7.3).
• 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 holes.
• 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. 7.5). 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 (Fig. 10). The first dowel hole therefore serves as a reference dimension, whereas the remaining dowel holes have tolerance for manufacturing inaccuracies.
• Cut the dowel holes: a) the first dowel hole by placing the stop latch at the side edge of the workpiece,

b) the following dowel holes according to the pencil markings made beforehand and the scale of the viewing window [10 3].

9 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.

Customer service and repair. Only through manufacturer or service workshops: Please find the nearest address at: www.festool.com/Service

Use only original Festool spare parts! Order No. at: www.festool.com/Service

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 screw.
• Attach the clamp lever to the hexagon screw again.

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.

10 Accessories, tools

For your own safety, use only original Festool accessories and spare parts.

Festool offers extensive accessories that enable you to use your machine effectively for a wide variety of applications, e.g.: routing circle, guide rails with rows of holes, routing aid, router base for bench-mounted use.

The accessory and tool order number can be found in the Festool catalogue or on the Internet under „www.festool.com“.

11 Environment

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: In accordance with European Directive on waste electrical and electronic equipment and implementation in national law, used electric power tools must be collected separately and handed in for environmentally friendly recycling.

Information on REACH:

www.festool.com/reach

12 General information

Imported into the UK by

Festool UK Ltd

1 Anglo Saxon Way

Bury St Edmunds

IP30 9XH

Great Britain

12 Example applications

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

A1.1 A1.4 Stable and non-twisting mitred frame joint.

A2 Very stable block frame joint.

A3 Very stable and non-twisting wood joints in frame and chair 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 additional stop 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.

13 Fault correction

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

	Fault Cause Adjustment
B1	burns blunt jointer bit use	sharp jointer bit
B2	expansion of dowel hole	jointing depth excessive (greater than 20 mm) with 5 mm jointing bit	reduce jointing depth
B3	dowel penetrates workpiece	incorrect workpiece thickness and/or jointing depth	adapt workpiece thickness and/or jointing depth
B4	Tears at edge of dowel hole	excessive feed rate reduce feed rate
B5	dowel hole not parallel to workpiece edge	workpiece has shifted during processing	secure workpiece properly
B6	dowel hole not at right angles (90°) to work-piece surface	a) deposits (e.g. chips) below the base plateb) angle guide not set exactly to 90°c) worked on without additional stop	a) remove depositsb) set angle guide to 90° exactlyc) use additional stop
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 narrower and allow you to make more accurate adjustments.

F