DF-500
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Domino® DF 500
Tenon Joiner
Tenon Joiner
Supplemental User’s Manual
WARNING To reduce the risk of serious injury, read and understand all safety
precautions and instructions in this manual before using this tool.
Limited Warranty
30 Day Money Back Guarantee
We are so confident that you will thoroughly enjoy our tools, that
we offer a 30 day money back guarantee. If you are not
1+2 Limited Warranty
Festool USA offers a 3-year limited warranty, one of the longest
in the industry. This warranty is valid on the pre-condition that
the tool is used and operated in compliance with the Festool
Conditions of 1+2 Limited Warranty
You are entitled to a free extended limited warranty (1 year + 2
years = 3 Years) for your Festool power tool. Festool USA is
responsible for all shipping costs during the first year of the
warranty. During the second and third year of the warranty, the
customer is responsible for shipping the tool to Festool. Festool
will pay for return shipping to the customer using UPS Ground
Service. All warranty service is valid 3 years from the date of
purchase on your receipt or invoice.
Excluded from the coverage under this warranty are: normal
wear and tear, damages caused by misuse, abuse, or neglect;
damage caused by anything other than defects in material and
workmanship. This warranty does not apply to accessory items
such as circular saw blades, drill bits, router bits, jigsaw blades,
sanding belts, and grinding wheels. Also excluded are "wearing
parts," such as carbon brushes, lamellas of air tools, rubber
collars and seals, sanding discs and pads, batteries, and Festool
gear (hats and t shirts).
The obligations of Festool USA in its sole discretion under this
warranty shall be limited to repair or replacement or a refund of
the purchase price for any Festool portable power tool that is
found to have a defect in materials or workmanship during the
completely satisfied, your full purchase price will be refunded,
excluding all freight charges.
operating instructions. Festool USA warrants that the specified
tool will be free from defects in materials and workmanship for a
term of 3 years from the date of purchase.
warranty period. FESTOOL USA SHALL NOT BE LIABLE FOR ANY
CONSEQUENTIAL, INCIDENTAL OR SPECIAL DAMAGES
REGARDLESS OF THE THEORY OF LAW ON WHICH THE CLAIM IS
BASED. ALL WARRANTIES IMPLIED BY STATE LAW, INCLUDING
THE IMPLIED WARRANTIES OR MERCHANTABILITY AND FITNESS
FOR A PARTICULAR PURPOSE ARE HEREBY LIMITED TO THE
DURATION OF THREE YEARS.
Some states in the U.S. and some Canadian provinces do not
allow the limitations on how long an implied warranty lasts, so
the above limitation may not apply to you. This warranty gives
you specific legal rights, and you may also have other rights that
vary from state to state in the U.S. and from province to province
in Canada.
With the exception of any warranties implied by state or province
law as limited above, the foregoing express limited warranty is
exclusive and in lieu of all other warranties, guarantees,
agreements, and similar obligations of Festool USA. Festool USA
makes no other warranty, express or implied, for Festool portable
power tools. No agent, representative, distributor, dealer, or
employee of Festool USA has the authority to increase or
otherwise change the obligations or limitations of this warranty.
Repairs
If your Festool power tools require repair, you must contact our
Service Department at (800) 554-8741 for authorization and
address details. No collect shipments will be accepted. No Festool
hats, t-shirts or other wearables may be returned. Also contact
our Service Department at the telephone number listed above if
you have any questions about warranty claim procedures.
Returns
If you need to return your Festool tools for any reason, please return it to the dealer from which you originally bought the tool.
Liability Statement
This product has been built to the high standards of Festool.
Please do not attempt to operate or repair this equipment without
adequate training. Any use, operation, or repair in contravention
of this document is at your own risk. By acceptance of this
system you hereby assume all liability consequent to your use or
misuse of this equipment. Festool USA assumes no liability for
incidental, special, or consequential damage of any kind.
Equipment specifications, applications, and options are subject to
change at the sole discretion of Festool USA without notice.
Proprietary Notice
All drawings and information herein are the property of Festool,
TTS Tooltechnic Systems AG & Co. KG. All unauthorized use and
reproduction is prohibited.
Written and Illustrated by Rick Christopherson.
© 2007-2008 TTS Tooltechnic Systems AG & Co. KG
All rights reserved. Printed in the United States of America and
Germany.
2 Domino DF 500 Tenon Joiner
Festool USA is a division of Tooltechnic Systems, LLC.
Festool is a trademark and service mark of TTS Tooltechnic
Systems AG & Co. KG
Domino, Plug-It, and Systainer are registered trademarks of TTS
Tooltechnic Systems AG & Co. KG
www.festoolusa.com
Contents
Limited Warranty .............................................2
30 Day Money Back Guarantee......................... 2
1+2 Limited Warranty..................................... 2
Conditions of 1+2 Limited Warranty.................. 2
Repairs ......................................................... 2
Returns......................................................... 2
Liability Statement ......................................... 2
Proprietary Notice........................................... 2
About This Manual............................................3
Tool Symbols................................................. 3
General Power Tool Safety Warnings ...............4
Work Area Safety........................................ 4
Electrical Safety.......................................... 4
Personal Safety........................................... 4
Power Tool Use and Care.............................. 4
Service...................................................... 5
Specific Safety Rules for Tenon Joiners .............. 5
Respiratory Exposure Safety Warnings .............. 5
Tool Description...............................................5
Technical Specifications................................... 5
Intended Use................................................. 5
Functional Description..................................... 6
Setup................................................................7
Setting Up a New Domino Joiner....................... 7
Setting the Fence Angle................................... 7
Setting the Fence Height ................................. 8
Setting the Mortise Width ................................ 8
Setting the Mortise Depth................................ 9
Changing the Mortising Bit............................... 9
Operation.......................................................10
Overview, General Notes, and Tips.................. 10
Plug-It® Power Cord...................................... 10
Turning On the Joiner.................................... 11
Using Dust Extraction.................................... 11
Using the Locating Pins or Edge Stop Dogs....... 11
Disabling/Retracting the Edge Stop Dogs.......... 12
Using the Base Support Bracket...................... 12
Using the Optional Narrow Frame Fence........... 12
Using the Optional Outrigger Guides................ 13
Applications ...................................................13
Edge Joining Boards...................................... 13
Making Butt Box Joints .................................. 14
Making Miter Box Joints................................. 15
Making Lock Tenon Joints .............................. 15
Making Frame Joints ..................................... 16
Making Carcase Butt Joints............................. 17
Making Three-Way Lock Miter Joints................ 18
Shortening a Domino Tenon’s Length............... 19
Creating Special Plunge Depths....................... 19
Tips for Applying Glue ................................... 19
Maintenance...................................................20
Routine Maintenance..................................... 20
Calibrating the Locating Pins or Edge Stop Dogs 21
Adjusting the Locating Pin........................... 21
Removing and Adjusting the Edge Stop Dogs.21
Calibrating the Horizontal Position Gauge......... 22
Accessories ....................................................23
Systainer (System Container)......................... 24
Troubleshooting.............................................25
About This Manual
Save These Instructions
It is important for you to read and understand this manual. The
information it contains relates to protecting YOUR SAFETY and
PREVENTING PROBLEMS. The symbols below are used to help you
recognize this information.
Indicates a potentially hazardous
WARNING!
CAUTION!
NOTICE:
Note:
situation which, if not avoided, could
result in death or serious injury.
Indicates a potentially hazardous
situation which, if not avoided, could
result in minor or moderate injury.
Indicates a potential situation which, if
not avoided, can result in property
damage or damage to the tool.
Indicates information, notes, or tips for
improving your success using the tool.
Instruction Manual 3
Tool Symbols
V Volts
W Watts
Hz Hertz
~ Alternating Current (AC)
n
No-load Speed
o
Ø Diameter
Class II Double Insulated
General Power Tool Safety Warnings
WARNING! Read all safety warnings and 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.
Work Area Safety
► Keep your work area clean and well lit. Cluttered or
dark work areas invite accidents.
► Do not operate power tools in explosive atmospheres,
such as in the presence of flammable liquids, gases,
or dust. Power tools create sparks which may ignite the
dust or fumes.
► Keep children and bystanders away while operating a
power tool. Distractions can cause you to lose control.
Electrical Safety
► Power tool plugs must match the outlet. Never modify
the plug in any way. Do not use any adapter plugs
with earthed (grounded) power tools. Unmodified plugs
and matching outlets will reduce risk of electric shock.
► Avoid body contact with earthed or grounded surfaces
such as pipes, radiators, ranges and refrigerators.
There is an increased risk of electric shock if your body is
earthed or grounded.
► Do not expose power tools to rain or wet conditions.
Water entering a power tool will increase the risk of electric
shock.
► Do not abuse the cord. Never use the cord for
carrying, pulling, or unplugging the power tool. Keep
cord away from heat, oil, sharp edges or moving
parts. Damaged or entangled cords increase the risk of
electric shock.
► When operating a power tool out doors, use an
extension cord suitable for outdoor use. Use of a cord
for outdoor use reduces the risk of electric shock.
► If operating a power tool in a damp location is
unavoidable, use a ground fault circuit interrupter
(GFCI) protected supply. Use of a GFCI reduces the risk
of electric shock.
► Never use an extension cord that is damaged,
including cuts, exposed wires, or bent/missing
prongs. Damaged extension cords increase the risk of fire
or electric shock.
► Use only extension cords rated for the purpose.
► Use only extension cords rated for the amperage of
this tool and the length of the cord. Using too small of
an extension cord can cause the cord to overheat.
Extension Cord Ratings
Cord Length Size (AWG)
<50 Ft. 14
50-100 Ft. 12
>100 Ft. Not
recommended
Personal Safety
► Stay alert, watch what you are doing, and use
common sense when operating a power tool. Do not
use a power tool while tired or under the influence of
drugs, alcohol, or medication. A moment of inattention
while operating power tools may result in serious personal
injury.
► Use personal protective equipment. Always wear eye
protection. Protective equipment such as dust mask, nonskid safety shoes, hard hat, or hearing protection used for
appropriate conditions will reduce personal injuries.
► Prevent unintentional starting. Ensure the switch is in
the off-position before connecting to power source,
picking up, or carrying the tool. Carrying power tools
with your finger on the switch or energizing power tools that
have the switch on invites accidents.
► Remove adjusting key or wrench before turning the
power tool on. A wrench or a key that is left attached to a
rotating part of the tool may result in personal injury.
► Do not overreach. Keep proper foot i ng and balance at
all times. This enables better control of the tool in
unexpected situations.
► Dress properly. Do not wear l oose clothing or jewelry.
Keep your hair, clothing, and gloves away from
moving parts. Loose clothes, jewelry, or long hair can be
caught in moving parts.
► If devices are provided for the connection of dust
extraction and collection facilities, ensure these are
connected and properly used. Use of dust collection can
reduce dust-related hazards.
► Always wear safety glasses complying with ANSI
Z87.1. Ordinary glasses are not proper protection.
Power Tool Use and Care
► Do not force the power tool. Use the correct power
tool for your application. The correct power tool will do
the job better and safer at the rate for which it is designed.
► Do not use the power tool if the switch does not turn
it on and off. Any power tool that cannot be controlled with
the switch is dangerous and must be repaired.
► Disconnect the plug from the power source before
making any adjustments, changing accessories, or
storing the tool. Such preventive safety measures reduce
the risk of starting the tool accidentally.
► Store idle tools out of reach of children and do not
allow persons unfamiliar with the power tool or these
instructions to operate the power tool. Power tools are
dangerous in the hands of untrained users.
► Maintain power tools. Check for misalignment or
binding of moving parts, breakage of parts and any
other condition that may affect the power tool’s
operation. If damaged, have the power tool repaired
before use. Many accidents are caused by poorly
maintained power tools.
► Keep cutting tools sharp and clean. Properly maintained
tools with sharp cutting edges are less likely to bind and are
easier to control.
► Use the power tool, accessories, and tool bits etc. in
accordance with these instructions, taking into
account the working conditions and the work to be
performed. Use of the power tool for operations different
from those intended could result in a hazardous situation.
► To reduce the risk of serious injury, never alter or
misuse the power tool.
4 Domino DF 500 Tenon Joiner
Service
► Have your power tool serviced by a qualified repair
person using only identical replacement parts. This
Specific Safety Rules for Tenon Joiners
► Mortising bits must be rated for at least the speed
recommended on the tool. Mortising bits running over
rated speed can fly apart and cause injury.
► Always use the fence. The fence protects the operator
from unintentional contact with the mortising bit. When the
fence is removed from the joiner, the spinning and
oscillating cutter is exposed and can cause serious injury.
► Keep hands away from the cutting area. Never place
your hand on the front face of the fence while the tool is
running.
► Use only Festool authorized mortising bits. Non-
approved mortising bits can come loose during operation.
► Never use dull or damaged mortising bits. Dull or
damaged mortising bits can cause the tool to lurch sideways
unexpectedly and lead to a loss of control of the power tool.
Respiratory Exposure Safety Warnings
Substantial or repeated inhalation of dust and other airborne
contaminants, in particular those with a smaller particle size,
may cause respiratory or other illnesses. Various dusts
created by power sanding, sawing, grinding, drilling and other
construction activities contain chemicals or substances known
(to the State of California and others) to cause cancer, birth
defects or other reproductive harm. Some examples of these
chemicals/substances are:
► lead from lead-based paints;
► crystalline silica from bricks, cement, and other masonry
products;
will ensure that the safety of the power tool is maintained.
► Do not operate the tool if the spring-loaded fence
does not return to its forward rest position. The fence
covers the mortising bit and prevents accidental contact. If
the slides of the fence do not move freely, have the tool
serviced immediately.
► Wait for the cutter to stop before setting the tool
down. An exposed cutter may engage the surface leading
to possible loss of control and serious injury.
► Use clamps or other practical way to secure and
support the workpiece to a stable platform. Holding the
work by hand or against your body is unstable and may lead
to loss of control.
► arsenic and chromium from chemically-treated lumber; and
► some wood dusts, especially from hardwoods, but also from
some softwoods such as Western Red Cedar.
The risk from these exposures varies, depending on how
often you do this type of work. To reduce your exposure to
these chemicals: work in a well ventilated area and use a
properly functioning dust extraction system. When the
inhalation of dust cannot be substantially controlled, i.e.,
kept at or near the ambient (background) level, the
operator and any bystanders should wear a respirator
approved by NIOSH for the type of dust encountered.
Tool Description
Technical Specifications
Power Consumption 420 Watts (3.5 amps @ 120 volts)
Motor Speed 25,500 RPM (no load)
Mortising Depth, Max. 28mm (1.1“)
Mortising Width, Max. 23mm (0.9”) + bit diameter
Mortising Bit Range 5mm, 6mm, 8mm, 10mm
Spindle Thread M6 x 0.75
Weight 3.2 kg (7 lbs)
Intended Use
The Domino tenon joiner is designed to produce mortises
in soft and hard wood, chip board, plywood and fiber
boards. All applications beyond this are regarded as
improper use. The tool should not be altered or used for
any other purpose other than as specified in these
operating instructions. Using the tool in contravention to
All metric dimensions are controlling. Mortising
bit dimensions are critical for safe operation,
and are presented in metric units only.
this manual may lead to injury and will void your
warranty. The user shall be responsible and liable for
accidents, injury, and property damage resulting from
misuse or abuse of this tool.
Instruction Manual 5
Functional Description
The Domino DF 500 Tenon Joiner is used to cut mortises in
wood for floating tenon joinery. Mortise and tenon joinery
is one of the oldest and strongest methods of joining
pieces of wood together. The Domino tenon joiner greatly
simplifies the task of cutting mating mortises in
workpieces to be connected together. A rotating and
oscillating cutter sweeps across the workpiece to quickly
and effortlessly cut a uniform mortise, in which a Domino
floating tenon is inserted.
Note: For newer models, the
locating pins are replaced with Guide
Item Name or Description Ref. Page(s)
Stop Dogs, as shown to the far right.
A Fence Body 9, 20
B Motor Housing 9, 20
C Auxiliary Handle 14, 15
D Fence Height Gauge 8, 14, 15
E Mortise Width Dial 8, 13
F Fence Height Locking Lever 8
G Power Switch 11
H Main Handle (barrel grip) ---
I Plug It® Power Inlet 10
J Depth Adjust Lever 8
K Depth Adjust Lock 8
M Board Thickness Gauge 8
Item Name or Description Ref. Page(s)
N Fence Angle Locking Lever 7
P Fence Angle Gauge 7, 15
Q Dust Extraction Port 11
R Baseplate 7, 17
S Outrigger Mounting Slot 12
T1 Locating Pins (qty. 2) 9, 11
T2 Edge Stop Dogs (qty. 2) 9, 11
U Mortising Bit Throat Opening ---
V Friction Pads (qty. 2) 25
W Horizontal Position Gauge 22, 12, 15
X Adjustable Fence Face 7, 8, 15
Y Fence Body Release Lever 9
Z Spindle Lock 9
6 Domino DF 500 Tenon Joiner
Setup
Setting Up a New Domino Joiner
Congratulations on your purchase of a new Festool Domino
Tenon Joiner. The Domino joiner is the finest portable
loose tenon joiner in the world. Before using your new
Domino joiner, make sure you fully read and understand
all of the precautions and safety information presented in
this manual.
WARNING! To reduce the risk of injury from
contact with a moving part, always unplug the
joiner before making any inspections or
adjustments, or before installing or removing any
accessory!
1. With the joiner unplugged, inspect the mortising bit.
Make sure it is not bent, chipped, or otherwise
damaged, and make sure the bit is fully tightened on
the spindle. (Refer to "
page 9 for more information).
CAUTION! Check regularly whether the
mortising bit is in good condition. Mortising bits
that are bent or damaged can break, and should
no longer be used.
2. Peel off the protective film from the bottom of the
joiner baseplate.
3. Set up the joiner for the appropriate type of operation
as described throughout the remainder of this section.
Changing the Mortising Bit" on
4. Make sure that the fence height and angle locking
levers are properly tightened.
5. Install the power cord into the Plug-It receptacle on the
joiner (refer to page 10 for more information).
6. Before you use the joiner, make sure to read the
Overview, General Notes, and Tips section on page 10.
Setting the Fence Angle
Some joints require the fence to be set to an angle from
the mortising bit. The most common application is for
making a mitered joint (see page 15).
1. Unplug the joiner for safety.
2. Loosen the fence angle locking lever by rotating it
counterclockwise about ¼-turn.
3. Rotate the fence face to the desired angle, and tighten
the locking lever.
Notes:
► The fence has detent stops at 22½, 45, 67½, and 90
degrees.
► Use the gauge pointer for setting the fence to angles
other than the ones listed above.
► For greater stability, the locking lever clamps down on
both right and left sides of the fence.
The table below provides some common miter angles for
easy reference.
Number of
Equal Sides
3 – Triangle 60 30
4 – Square 45 45
5 – Pentagon 36 54
Mitersaw
Angle
Domino
Angle
Number of
Equal Sides
6 – Hexagon 30 60
7 – Heptagon 25.7 64.3
8 – Octagon 22.5 67.5
Mitersaw
Angle
Domino
Angle
Instruction Manual 7
Setting the Fence Height
The height of the fence needs to be adjusted
depending on the type of joint being made and the
thickness of the material being joined. Refer to the
Applications section beginning on page 13 for more
information about the optimal fence height for the
specific application. There are two features available
for setting the fence height; the height gauge and the
board thickness gauge.
Note: It is not necessary to set the mortise
position to be exactly in the center of a
board. See the
on page 13 for more information about
mortise position.
Height Gauge
The height gauge shows the distance between the
bottom of the fence face and the centerline of the
mortising bit. Use this gauge to set the mortise height
relative to the surface of the workpiece.
Note: Make sure to retract the Board
Thickness Gauge to its lowest setting when
using the Height Gauge.
Applications section beginning
2. To use the board thickness gauge:
a. Raise the fence above the board thickness gauge.
b. Slide the gauge in or out until the thickness of the
workpiece (in mm) is shown in the window.
c. Lower the fence down until it touches the gauge.
d. Tighten the locking lever.
3. To use the height gauge:
a. Make sure the board thickness gauge is retracted out of
the way.
b. Raise or lower the fence until the pointer is pointing to
the desired height on the gauge.
c. Tighten the locking lever.
Board Thickness Gauge
The numbers printed on the gauge represent the
thickness of the workpiece (in mm) and the mortise
height will be centered in the workpiece. Use this
gauge for setting the fence height based on the
thickness of the workpiece without needing to
calculate the center distance.
Note: Do not use the board thickness gauge
for mitered joints, because this will place the
mortise too close to the edge of the joint.
1. Loosen the fence height locking lever by turning it
¼-turn counterclockwise.
Setting the Mortise Width
The width of the mortise slot can be increased to permit some
side-to-side flexibility in the tenon position. The mortise width
dial has three positions. In the standard (smallest) position,
the Domino tenon will fit snugly into the mortise slot. In the
middle position, the mortise slot will be 6 mm wider than the
Domino tenon. In the widest position the mortise slot will be
10 mm wider than the Domino tenon.
Important Notes
NOTICE: To avoid damaging the tool, follow
the notes below.
► Never force the dial to turn.
► Rotate the adjustment dial only when the motor is running.
► Never rotate the dial during a plunging operation. This can
bend or break the mortising bit, and can also damage the
machine.
8 Domino DF 500 Tenon Joiner
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