Festool DF 500 User Manual

Domino® DF 500

Tenon Joiner

Tenon Joiner Supplemental
Extended User’s Manual

Important: Read and understand all
instructions before using this tool.

Warranty

Conditions of 1+2 Warranty

You are entitled to a free extended warranty (1 year + 2
years = 3 years) for your Festool
be responsible for all shipping costs during the first year of
the warranty. During the second and third year of the

Festool Limited Warranty

This warranty is valid on the pre-condition that the tool is
used and operated in compliance with the Festool operating
instructions. Festool warrants, only to the original consumer
purchaser, that the specified tool will be free from defects in
materials and workmanship for a term of one year from the
date of procurement. Festool makes no other warranty,
express or implied, for Festool portable power tools. No
agent, representative, distributor, dealer or employee of
Festool has the authority to increase or otherwise change the
obligations or limitations of this warranty. The obligations of
Festool in its sole discretion under this warranty shall be
limited to the repair or replacement of any Festool portable
power tool that is found to be defective as packaged with the
User Manual.

Excluded from 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, and batteries.

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power tool. Festool shall

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.

Festool portable power tools requiring replacement or repair
are to be returned with the receipt of purchase to Festool
(call 800-554-8741 for address details).

IN NO EVENT SHALL FESTOOL BE LIABLE FOR ANY
CONSEQUENTIAL OR INCIDENTAL DAMAGES FOR
BREACH OF THIS OR ANY OTHER WARRANTY,
EXPRESSED OR IMPLIED WHATSOEVER. ALL
WARRANTIES IMPLIED BY STATE LAW, INCLUDING
THE IMPLIED WARRANTIES OF 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. With the
exception of any warranties implied by state or province law
as hereby limited, the foregoing express limited warranty is
exclusive and in lieu of all other warranties, guarantees,
agreements and similar obligations of Festool. This warranty
gives you specific legal rights and you may also have other
rights which vary from state to state in the U.S., and
province to province in Canada.

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
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 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 TTS Tooltechnic Systems AG & Co. KG

All rights reserved. Printed in the United States of America and/or Germany.

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

2 Domino DF 500 Tenon Joiner

Contents

Warranty ..............................................................................2

Conditions of 1+2 Warranty .........................................2

Festool Limited Warranty .............................................2

Liability Statement .........................................................2

Proprietary Notice..........................................................2

General Safety Rules.........................................................4

Work Area Safety .......................................................4

Electrical Safety ..........................................................4

Extension Cords .........................................................4

Personal Safety ...........................................................4

Tool Use and Care......................................................4

Service..........................................................................5

Specific Safety Rules for Tenon Joiners .......................5

Respiratory Exposure Warning....................................5

Tool Description ................................................................5

Technical Specifications.................................................5

Symbols............................................................................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

Turning On the Joiner..................................................11

Using Dust Extraction..................................................11

Using the Locating Pins...............................................11

Using the Base Support Bracket .................................12

Using the Optional Outrigger Guides.......................12

Using the Optional Narrow Frame Fence................. 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 Appyling Glue ...............................................19

Maintenance .....................................................................20

Routine Maintenance................................................... 20

Calibrating the Locating Pins .....................................21

Calibrating the Horizontal Position Gauge ..............21

Accessories ........................................................................22

Systainer (System Container) .....................................23

Troubleshooting ..............................................................24

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Power Cord .................................................... 10

Instruction Manual 3

General Safety Rules

!WARNING: Read and understand all instructions listed below.

Failure to heed instructions may result in personal injury,
electrocution, or fire hazard.

Work Area Safety

► Keep your work area clean and well lit. Cluttered benches and

dark 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.

Electrical Safety

► Double insulated tools are equipped with a polarized plug

(one blade is wider than the other). This plug will fit in a
polarized outlet only one way. If the plug does not fit fully into
the outlet, reverse the plug. If it still does not fit, contact a
qualified electrician to install a polarized outlet. Do not change
the plug in any way. Double insulation eliminates the need for
the three wire grounded power cord.

Extension Cords

All due care should be practiced while using extension cords with
this tool.

► When operating a power tool outside, use an outdoor extension

cord marked “W-A” or “W”. These cords are rated for outdoor
use and reduce the risk of electric shock.

► Never use an extension cord that is damaged, such as cuts,

exposed wires, or bent/missing prongs.

► Use only extension cords rated for the purpose.

Personal Safety

► Stay alert, watch what you are doing, and use common sense

when operating a power tool. Do not use the 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.

► Dress properly. Do not wear loose clothing or jewelry. Contain

long hair. Keep your hair, clothing, and gloves away from
moving parts. Loose clothes, jewelry, or long hair can be caught

in moving parts.

► Avoid accidental starting. Be sure the switch is off before

plugging in the power cord. Carrying tools with your finger on
the switch or plugging in tools that have the switch on invites
accidents.

Tool Use and Care

► 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.

► Do not force the tool. Use the correct tool for your application.

The correct tool will do the job better and safer at the rate for
which it is designed.

► Do not use the tool if the switch does not turn it on or off. Any

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

Save These Instructions

► Keep bystanders, children, and visitors away while operating a

power tool. Distractions can cause you to lose control.

► Avoid body contact with grounded surfaces such as pipes,

radiators, ranges and refrigerators. There is an increased risk of
electric shock if your body is 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 to carry the tools or

pull the plug from an outlet. Keep cord away from heat, oil,
sharp edges or moving parts. Replace damaged cords
immediately. Damaged cords increase the risk of electric shock.

► 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 tool to lose power and damage the tool.

Extension Cord Ratings

Cord Length Size (AWG)

<50 Ft. 14

50-100 Ft. 12

100-150 Ft. 10

>150 Ft. Not recommended

► Remove adjusting keys or wrenches before turning the 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 footing and balance at all times.

Proper footing and balance enables better control of the tool in
unexpected situations.

► Use safety equipment. Always wear eye protection. Dust mask,

non-skid safety shoes, hard hat, or hearing protection must be
used for appropriate conditions. (Ordinary glasses are NOT
proper eye protection.)

► If devices are provided for the connection of dust extraction

and collection facilities, ensure these are connected and
properly used. Use of these devices can reduce dust-related

hazards.

preventive safety measures reduce the risk of starting the tool
accidentally.

► Store idle tools out of reach of children and other untrained

persons. Tools are dangerous in the hands of untrained users.

► Maintain tools with care. Keep cutting tools sharp and clean.

Properly maintained tools with sharp cutting edges are less likely
to bind and are easier to control.

► Check for misalignment or binding of moving parts, breakage

of parts, and any other condition that may affect the tool's
operation. If damaged, have the tool serviced before using.

Many accidents are caused by poorly maintained tools.

4 Domino DF 500 Tenon Joiner

► Use only accessories that are recommended by the

manufacturer for your model. Accessories that may be suitable
for one tool may become hazardous when used on another tool.

► Use the power tool, accessories and tool bits etc., in accordance

with these instructions and in the manner intended for the

Service

► Tool service must be performed only by qualified repair

personnel. Service or maintenance performed by unqualified
personnel could result in a risk of injury.

Specific Safety Rules for Tenon Joiners

!WARNING: Risk of personal injury.

► Keep hands away from the cutting area. Never place your hand

on the front face of the fence while the tool is running.

► Never operate the joiner without the fence attached. When the

fence is removed from the joiner, the spinning and oscillating
cutter is exposed and can cause serious injury.

► 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.

► Do not operate the tool if the spring-loaded fence does not

return to its forward rest position. The fence covers the

particular type of power tool, taking into account the working
conditions and the work to be performed. Use of the power tool

for operations different from those intended can be hazardous.

► When servicing a tool, use only identical replacement parts.

Use of unauthorized parts or failure to follow maintenance
instructions may create a risk of electric shock or injury.

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.

► Wear eye and hearing protection. Always use safety

glasses. Every day eyeglasses are NOT safety glasses. USE
CERTIFIED SAFETY EQUIPMENT. Eye protection
equipment should comply with ANSI Z87.1 standards.
Hearing equipment should comply with ANSI S3.19
standards.

Respiratory Exposure Warning

Various dust created by power sanding, sawing, grinding, drilling
and other construction activities contains chemicals known (to the
State of California) to cause cancer, birth defects or other
reproductive harm. Some examples of these chemicals are:

► lead from lead-based paints,
► crystalline silica from bricks, cement, and other masonry

products,

► arsenic and chromium from chemically-treated lumber.

Tool Description

Technical Specifications

Power Consumption 420 Watts (3.5 amps @ 120 volts)
Motor Speed 24,300 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)

All metric dimensions are binding. Mortising bit dimensions are critical
for safe operation, and are presented in metric units only.

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 work with approved safety
equipment, such as dust masks that are specially designed to filter
out microscopic particles.

Symbols

V Volts

W Watts

Hz Hertz

~ Alternating Current (AC)

no No-load Speed

Ø Diameter

Class II Double Insulated

Intended Use

The Domino tenon jointer 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 this manual will
void your warranty and may lead to injury. The user shall be responsible and liable for damages and accidents 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.

Item Name or Description Ref. Page(s)

Fence Body 9, 20

a

Motor Housing 9, 20

b

Auxiliary Handle 14, 15

c

Fence Height Gauge 8, 14, 15

d

Mortise Width Dial 8, 13

e

Fence Height Locking Lever 8

f

Power Switch 11

g

Main Handle (barrel grip) ---

h

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Plug It

i

Depth Adjust Lever 8

j

Depth Adjust Lock 8

k

Board Thickness Gauge 8

m

6 Domino DF 500 Tenon Joiner

Power Inlet 10

Item Name or Description Ref. Page(s)

Fence Angle Locking Lever 7

n

Fence Angle Gauge 7, 15

p

Dust Collection Port 11

q

Baseplate 7, 17

r

Outrigger Mounting Slot 12

s

Locating Pins (qty. 2) 9, 11

t

Mortising Bit Throat Opening ---

u

Friction Pads (qty. 2) 24

v

Horizontal Position Gauge 21, 13, 15

w

Adjustable Fence Face 7, 8, 15

x

Fence Body Release Lever 9

y

Spindle Lock 9

z

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: Always disconnect the tool from the

power supply 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 "Changing the Mortising Bit" on page
9 for more information).

WARNING: Check regularly whether the mortising

bit is in good condition. Mortising bits that are bent or
damaged 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.

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.

Number of sides Mitersaw Angle Domino Angle

3 – Triangle
4 – Square
5 – Pentagon

60 30
45 45
36 54

Number of sides Mitersaw Angle Domino Angle

6 – Hexagon
7 – Heptagon
8 – Octagon

30 60

25.7 64.3

22.5 67.5

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.

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.

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. 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.

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.

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.

Setting the Mortise Width

The width of the mortise slot can be increased to permit some
side-to-side flexibility in the tenon position. 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

► 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