Domino XL DF700
Contents
1. 14 Domino XL DF700 Making Butt Box Joints Butt box joints are typically used in general box construction 7 or for drawer construction The Domino tenons strengthen the joint without the need for additional fasteners The example below highlights drawer construction but the same techniques are used on other types of box construction Construction Tips For drawer construction with a separate drawer front the front and rear of the box should be Captive as shown below gt The drawer front is installed onto the drawer box after the box has been assembled gt This increases the strength of the drawer because the tenons are in shear perpendicular to the operation of opening and closing the drawer gt The ends of the side boards are concealed by the sepa rate drawer front For drawer construction without a separate drawer front the Sides should be Captive and the Front Rear should be the Caps the reverse of the image below gt For cabinet carcase construction the Top Bottom of the carcase should be Captive also see Making Carcase Butt 4 Joints on page 17 ou BR UW Front Rear Captive side Cap Machining the Captive Side Mortises 1 Choose a Domino tenon size to be less than or equal to 1 3 of the board s thickness 2 Set the height of the fence so the Domino tenons are in the center of the board s thickness 3 Set the mortise depth according to the instructio2. J Ss T Using the Base Support Bracket The base support bracket stabilizes the joiner when mortis ing on the face of a narrow board as shown to the right The base support bracket mounts to the underside of the joiner with two thumbscrews Stand the joiner upright on a flat surface when installing the bracket to ensure it is flush with the front of the joiner I Support Bracket R Supplemental Owner s Manual To retract a pin push in on it until it clicks into place To release the pins press the release button on the side of the fence There is a release button for the left and right sets of pins The pins are spring loaded so it is not necessary to retract a pin when not in use However retracting unused pins will prevent them from pushing your workpiece away from the fence Using the Optional Cross Stops The optional cross stops extend the position of the locat DF500 versus DF700 Setup ing pins for wider tenon spacing These are also adjustable so the spacing can be tailored to the needs of the specific application The new model cross stop is compatible with both DF500 and DF700 joiners by inverting the stop pin assembly This changes the height of the stop pins to line up with existing Note The two cross stops are specific for right and mortises The previous model will still fit the DF700 joiner D left hand mounting such that the locking levers point but the pins won t line up with existing m
3. gt Apply glue to the workpiece face and the mortise slots before inserting the tenons into the slots 18 has been cut to length Cut the tenon to the desired length with either a hand saw or miter saw Removal Slot gt When applying glue for the tenons you can either apply glue into the mortise slots spread a thin layer across the Domino tenons or both gt When the tenon is the primary structure holding the joint together you should apply the glue at least to the tenon or both The Domino tenons have small glue pockets and ridges that will hold glue as the tenon slides into the mortise slot gt When applying glue to the mortise slot take care not to use too much glue as there is not enough space for the excess glue to squeeze out past the tenon Domino XL DF700 Maintenance WARNING Any maintenance or repair work NOTICE Do not use compressed air to clean the that requires opening of the motor or gear hous O motor housing of the tool as you could inject for ing should be carried out only by an authorized eign objects into the motor through the ventilation Customer Service Center see your dealer for openings information on locating a service center NOTICE Certain cleaning agents and solvents are WARNING To reduce the risk of electrocution or harmful to plastic parts Some of these include but other personal injury always unplug the tool from are not limited to Gasoline Aceton
4. ccccceeeeees 12 SIV CS a cautions ea deaeantesaesaseeuorsesansctenunen Using the Optional Narrow Frame Fence 13 Specific Safety Rules for Tenon Joiners Using the Optional Hand Rail Fence 13 Respiratory Exposure Safety Warnings sss05 PDINCAUIONS sasssanesatetansansicsssavavansvevecnesssasewasuss 14 TOOL Description iscccssnscanisnssssassccaedetsanncnnseencnnens Edge Joining Boards cccccsseeseneceeeseensnenteees 14 Technical SpecificationS ccccceeeeeeeeeeeeeeeeeeeenees Making Miter Box Joints cccc cece ee eeeeee eee eeees 14 Intended USC rrura Making Butt Box Joints ccc cece eee eee e ee ee eee 15 Functional Description cece eee e cesses seen eeeeaaee Making Frame Joints cccececeseeeneeeceeneneneeees 16 SaN s E E E E Making Carcase Butt JOINtS ccccceeee eee eee ees 17 Setting Up a New Domino Joiner c cece eee Making Lock Tenon Joints c cece ee eeeee eee eeeees 18 Setting the Fence Angle cccscccccenneeeeessenunens Shortening a Domino Tenon s Length 18 Setting the Fence HeIGNt ccccceeeneeeeeeseennnens TIPS for Applying GlUC ccc cceeeesessseeneeneeeeeenenees 18 Setting the Mortise Width cccce cece ee eee eens MEALIVUR NAINCG ssivacctnsanicctvassisscenscetenrtnadencieasinanis 19 Setting the Mortise Depth c cece eee eee eee eens Routine Maintenance
5. ccc cccc cece eee eee e ee eee ee eees 19 Changing the Mortising Bit cccccee essen eens Calibrating the Sight Gauge c cece cece eee eee 20 ODS PALIONN wwidacivexntesivisaverscccrnsesisaxesursteusussiiases 10 Troubleshooting cssssscccccceesennneeeeeeeeeseeeennaas 21 Overview General Notes and TipS 0085 10 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 WARNING Indicates a potentially hazardous situation which if not avoided could result in death or serious injury CAUTION Indicates a potentially hazardous situation which if not avoided could result in minor or moderate injury NOTICE Indicates a potential situation which if not avoided can result in property damage or damage to the tool D Note Indicates information notes or tips for improving your success using the tool Tool Symbols V Volts W_ Watts Hz Hertz Alternating Current AC n No load Speed Diameter Class II Double Insulated Supplemental Owner s Manual 3 General Power Tool Safety Warnings A WARNING Read all safety warnings and instructions Failure to follow the warnings and instructions may result in electric shock fire and or serious injury
6. Domino XL DF700 Tenon Joiner Tenon Joiner Supplemental User s Manual WARNING To reduce the risk of serious injury read and understand all safety A 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
7. Work Area Safety gt Keep your work area clean and well lit Cluttered or dark work areas invite accidents gt Do not operate power tools in explosive atmospheres such as in the presence of flammable liquids gases or dust Power Electrical Safety gt 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 gt 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 gt Do not expose power tools to rain or wet conditions Water entering a power tool will increase the risk of electric shock gt Do not abuse the cord Never use the cord for carrying pull ing 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 gt When operating a power tool outdoors use an extension cord suitable for outdoor use Use of a cord for outdoor use reduces the risk of electric shock Personal Safety gt 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 seri
8. 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 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 Returns 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 the 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 ab
9. or replace the bits as necessary gt Never attempt to sharpen the mortising bits yourself The mortising bits should be sharpened only by a qualified sharpening service gt For best results only the tip of the bit should be ground not the sides Cleaning and Maintenance 1 Blow off the exterior of the machine with low pressure compressed air to remove sawdust but do not blow air directly into the air cooling vents on the back of the motor as this can drive debris into the motor 2 Blow out impacted sawdust from the mortising bit area NOTICE To avoid getting debris inside the guide O tubes do not remove the fence body from the motor housing when the joiner is coated with sawdust 3 With the exterior of the joiner free from sawdust remove the fence body from the motor housing and clean the slide components a With a soft cotton cloth wipe down the linear rails Supplemental Owner s Manual 19 Calibrating the Sight Gauge The horizontal position gauge also called the sight gauge is used for aligning Domino tenons to a pencil mark on the workpiece If the gauge is not perfectly centered over the mortising slot the two workpieces will not be aligned when the joint is assembled Calibration Procedure 1 Take two pieces of scrap wood and draw a thin line on each piece where a tenon is to be placed You do not need to be concerned with how the edges line up a e on a 1 Fs Pu laiale siali a
10. use the stop pin in the previous mortise slot Standard Width Tips for Successful Joining Use the stop pins page 11 for the first mortise slot with the mortise width lever set to the narrow setting page 8 gt For subsequent mortise slots you can keep the mortise width at the minimum Making Miter Box Joints Without tenons miter box joints are fairly weak because the Setup and Machining joint is predominately endgrain to endgrain Tenons signifi cantly increase the strength of the joint and make it easier to assemble and clamp the pieces 1 Tilt the fence to the appropriate angle Refer to the table on page 7 for miter angles for multi sided boxes 2 Lower the fence to the desired height Note that the mortise should be close to the inside corner to avoid gt For thinner materials keep the mortise close to the inside penetrating through the workpiece corner This minimizes the chances for boring all the way 3 through the workpiece Construction Tips Tip Before milling the mortise double check your depth settings to ensure you don t cut all the way through gt For very thin materials it may be necessary to shorten 4 Plunge the joiner as shown below the Domino tenon length as described on page 18 ove an k f hick k For thicker materials stacked mortises can be used gt The stacked mortises are used for thicker stoc 6 Grasp the joiner by the auxiliary handle for best control
11. Domino joiner firmly to the work surface Plunging too slow can cause the mortise slots to be tilted slightly Make sure the proper plunge depth is set Make sure the mortising bit is not broken Make sure the joiner is tight to the face of the workpiece The mortising bit may have been sharpened too many times and is too short Excessive dust may be present inside the linear slide Excessive glue may be present at the bottom of the mortise gt Plunging speed too fast Slow down the rate of your plunge gt Low grade materials and plywoods will tear out more than solid woods Decreasing your plunging speed will improve the results but may not eliminate the problem completely gt Dull or broken mortising bit gt The plunge speed is too fast and the bit is not cutting the sides properly Slow down the plunge speed Supplemental Owner s Manual 21
12. For plywoods especially low grade construction plywoods the Domino tenon is much stronger than the surrounding wood so it is best to maximize the strength of the sub strate by minimizing the thickness of the tenon distance between a mortise and the wood surface should all be equal to or larger than the thickness of the tenon Minimum spacing equal to one domino thickness A Minimum Spacing Equal to Domino Thickness Twist to x Domino XL DF700 Using Dust Extraction The Domino joiner is intended to be used with a dust extrac tion system Using the machine without dust extraction will cause it to clog with wood chips When installing a Festool dust extraction hose onto the dust port of the machine it is easiest to insert the hose at an angle and then push it on the rest of the way as shown to the right Note If you have a non Festool vacuum system and your vacuum hose does not fit the dust extrac tion port a Festool vacuum hose will fit many other brands of vacuums Using the Stop Pins On the front of the fence are 3 pair of stop pins These are used to register the tool against the edge of the workpiece or against a previously machined mortise slot and provide rapid and precise placement of the tool on the workpiece The distances between the locating pin and the center of the mortise slot are 20 37 and 50 mm The pins are spring loaded but can also be locked in the retracted position A
13. circuit interrupter GFCI protected supply Use of a GFCI reduces the risk of electric shock gt 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 gt Use only extension cords rated for the purpose p gt 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 50 100 Ft gt 100 Ft tool on A wrench or a key that is left attached to a rotating part of the tool may result in personal injury gt Do not overreach Keep proper footing and balance at all times This enables better control of the tool in unexpected situations gt Dress properly Do not wear loose 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 extrac tion and collection facilities ensure these are connected and properly used Use of dust collection can reduce dust related hazards gt Always wear safety glasses complying with ANSI Z87 1 Ordinary glasses are not proper protection the tool accidentally gt Store idle tools out of reach of children and do not allow persons unfamiliar with the power tool or these instructions
14. ction is prohibited Written and Illustrated by Rick Christopherson 2012 TTS Tooltechnic Systems AG amp Co KG All rights reserved Printed in the United States of America and Germany 2 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 Festool USA is a division of Tooltechnic Systems LLC Festool is a trademark and service mark of TTS Tooltechnic Systems AG amp Co KG Domino Plug It and Systainer are registered trademarks of TTS Tooltechnic Systems AG amp Co KG www festoolusa com Domino XL DF700 Contents About This Manual sssssssssunnnnnnnnnnnnnnnnnnnnnnnnnn Choosing the Right Domino Tenon Size 10 VOOM SYINIDO S ersin pni on Er A E Domino Tenon Placement Guidelines 10 General Power Tool Safety Warnings Piug It Power COrd ciscicsstcccsescsewenscsceensnaceaeaees 10 Work Area Safety sisisicosistssicsetasiariarsscattenionns USING Dust EXUFACTION serren innin na 11 Electrical Safety ririciisiarcsrerinaae i USING the Stop PiNS traircisneeana ai 11 Personal Safety ssisecencaeeexnanasneseseasenenusaddesaesanns Using the Base Support Bracket cceeeeeee 11 Power Tool Use and Care cece cece ec eeeeen eee eeeees Using the Optional Cross Stops
15. dow c Lower the fence down until it touches the stop d Tighten the locking lever 3 To use the height gauge a Make sure the Height Stop 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 Mortise Width Lever Mortise Width Indicator Domino XL DF700 Setting the Mortise Depth The mortising depth determines how deep into the work If you are frequently switching depth settings use the two piece the mortising bit penetrates This needs to be adjusted limit stops to assist in setting those positions This is also for different sized tenons In most cases the tenon should helpful when working with thin materials and you set the be centered across the joint and the depth of the mortise maximum limit to be less than your material thickness should be 2 the length of the tenon However in some cases you may want to have more of the tenon in one piece than the other lower Domino tenon pictured below In this case the sum of the two depths must equal the length of the tenon In the offset tenon example below the Domino tenon is 50 mm long the left mortise is 35 mm deep and the right mortise is 15 mm deep To set the depth position press down on one of the two release buttons and slide the adjustment pointer to the desired setting Centered Depth Adjustment Release Button s Changing t
16. e Methyl Ethyl the power supply outlet before performing any Ketone MEK Carbonyl Chloride cleaning solutions maintenance or repair work on the tool containing Chlorine Ammonia and household clean ers containing Ammonia Routine Maintenance The Domino tenon joiner does not require much routine b With low pressure compressed air blow out any dust maintenance except for cleaning For best performance from inside the guide tubes and long life of the Domino tenon joiner keep the machine c With a soft cotton cloth wipe down the interior of the clean linear bearings interior of the guide tubes gt To ensure proper cooling of the tool and motor the cooling 4 vents in the motor housing must always be kept clear and clean With a clean cotton cloth not the same cloth used previ ously apply a coating of light weight machine oil to the linear rails and or linear bearings gt Keep the linear rails guide tubes and linear bearings 5 clean and free from sawdust Replace the fence body and with the plunge depth set to maximum plunge the joiner in and out several times to gt Never store the joiner with the fence body separated from spread the lubricant into the internal linear bearings the motor housing as this can permit dust and debris to 6 Wipe off the excess oil from the linear rails enter the guide tubes P gt Periodically inspect the mortising bit s for damage wear or dullness Re sharpen
17. en the clamping knob on the adjustable stop pin and Clamp slide the pin to the desired position Locking 4 Before tightening the clamping knob make sure both Setscrew pointers on the locating pin are pointing to the same measurement on the outrigger arm Stop Pin Assembly 12 Domino XL DF700 Using the Optional Narrow Frame Fence The optional narrow frame fence also called the trim stop is used to securely hold small workpieces for cutting mortises Installing the Narrow Frame Fence 1 With the fence tilted to 90 degrees slide the narrow frame fence over the fence face of the Domino joiner as Shown Make sure the narrow frame fence is fully seated onto the joiner s fence 2 Slide the two latch tabs inward 3 Tighten the two thumbscrews Setting the Fence Width 1 Loosen the two green thumbscrews on the bottom of the fence 2 Place the workpiece between the two guides and slide the guides inward 3 Use the position gauge on the Domino joiner fence face to center the workpiece 4 With the side guides tight to the workpiece and the workpiece centered in the position gauge tighten the two thumbscrews Hint Make note of where the workpiece lines up on the sight gauge and use the sight gauge when cutting the mortise on the mating frame for a T joint frame Using the Optional Hand Rail Fence The optional hand rail fence is used to help stabilize rounded If the hand rail fence is not sitting p
18. erfectly centered on the workpieces that won t otherwise rest flat against the fence mortising location it can be shifted to the side by adjusting the four gib screws Installing the Hand Rail Fence 1 With the fence tilted to 90 degrees slide the hand rail fence over the fence face of the Domino joiner as shown Make sure the hand rail fence is fully seated onto the joiner s fence 2 Slide the two latch tabs inward 3 Tighten the two thumbscrews Gib Screws 4 Supplemental Owner s Manual 13 Applications Edge Joining Boards Edge joining boards is a common method for creating wide setting but you may find it easier to set the mortise width boards from a series of narrower boards The Domino dial to the next widest setting tenons add strength to the joint and also assist in aligning gt Place the mortise slots 6 to 12 inches apart for standard the boards to be flush joints but this spacing should be decreased for joining For edge joining boards a series of tenons are placed down plywoods or when a stronger joint is needed the length of the joint The first tenon is used to register the two boards horizontally so it is milled at standard width The remaining tenons align the boards flush and may be milled with an oversize width gt Instead of marking the mortise placements with pencil lines you can use the optional cross stops page 12 to evenly space the mortises down the length of the boards To do this
19. ese exposures varies depending on how gt some wood dusts especially from hardwoods but also from some softwoods such as Western Red Cedar to the State of California and others to cause cancer birth often you do this type of work To reduce your exposure to defects or other reproductive harm Some examples of these these chemicals work in a well ventilated area and use a chemicals substances are properly functioning dust extraction system When the inhala tion of dust cannot be substantially controlled i e kept at or near the ambient background level the operator and any gt crystalline silica from bricks cement and other masonry bystanders should wear a respirator approved by NIOSH for products the type of dust encountered Tool Description p gt lead from lead based paints Technical Specifications All metric dimensions are controlling Mortising bit dimen sions are critical for safe operation and are presented in pS ed nee Intended Use The Domino tenon joiner is designed to produce mortises in tool in contravention to this manual may lead to injury and will soft and hard wood chip board plywood and fiber boards All void your warranty The user shall be responsible and liable for applications beyond this are regarded as improper use The accidents injury and property damage resulting from misuse or tool should not be altered or used for any other purpose other abuse of this tool than as specified in
20. f the shelf is thin less than 30mm tip it down with the bottom side facing up 4 Clamp the two pieces together to prevent them from moving 5 With the Domino baseplate resting on the face of the side piece plunge the joiner into the edge of the shelf Do not use the fence for height positioning i H 4 i ty F t 1 ey T m 1 oe i 4 n _ i al z i i PE E 1 7 Horizontal Veg Shelf Piece 2 Side Picco 6 With the joiner standing upright and its baseplate against the edge of the shelf plunge downward into the side wall of the cabinet see image below 7 Repeat these steps for each of the shelves 8 When you repeat this process for the other side wall make sure you keep the same side of the shelf facing up e ag e um i d hr i Be i i a j Making Lock Tenon Joints A locked tenon joint is any type of joint with two or more tenons at opposing angles Once the opposing tenon s are inserted the joint cannot be disassembled With the exception of the Three way Locked Miter Joint page 18 at least one of the tenons must be exposed so it can be inserted after the joint is assembled This is referred to as the Locking Tenon There are many variations of a locked tenon joint but the simplest involve a mitered corner in a box or flat frame The miter angle provides an easy reference for the two tenon angles In the example shown to the
21. f the tenons Use the Make sure to securely clamp the workpiece to the bench sight gauge on the joiner s fence to position the joiner over when mortising a mitered joint the pencil line a N A T Fo p a _ n a i N a W i S a PS 3 a ede i gt m Sa vm For narrow frame stock the optional narrow frame fence also called the trim stop can be used to securely hold the workpiece shown below i ee Cope and Stick Stile and Rail Frames Domino tenons can also be used to strengthen cope and stick frame construction too bottom right picture This is typically found in raised panel door frames It is important to note that the two frame pieces overlap so the depth of the mortise needs to be extended The amount that each mortise needs to be extended is one half the amount of overlap Example A typical stile and rail router bit set has a profile l a width overlap of 3 8 inch about 10mm For a 40mm long me a tenon instead of plunging 20mm deep you should increase this to 25mm for both workpieces Stick Profile ok Mitered Frames When making mitered frames position the tenon closer to the inside corner This reduces the likelihood of cutting the mortise all the way through the workpiece 16 Domino XL DF700 Making Carcase Butt Joints Using tenoned butt joints is an effective method for con structing a cabinet carcase The tenons provide a str
22. fence The fence protects the operator from return to its forward rest position The fence covers the mor unintentional contact with the mortising bit When the fence tising bit and prevents accidental contact If the slides of the is removed from the joiner the spinning and oscillating cutter fence do not move freely have the tool serviced immediately is exposed and can cause serious injury gt Wait for the cutter to stop before setting the tool down An gt Keep hands away from the cutting area Never place your exposed cutter may engage the surface leading to possible hand on the front face of the fence while the tool is running loss of control and serious injury gt Use only Festool authorized mortising bits Non approved gt Use clamps or other practical way to secure and support the mortising bits can come loose during operation workpiece to a stable platform Holding the work by hand or gt Never use dull or damaged mortising bits Dull or damaged against your body is unstable and may lead to loss of control Respiratory Exposure Safety Warnings gt Substantial or repeated inhalation of dust and other airborne arsenic and chromium from chemically treated lumber and 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 The risk from th
23. he Mortising Bit Different mortising bits are available for a variety of Domino 3 Loosen the mortising bit by turning it counterclockwise tenon sizes The DF700 comes equipped with a 12mm bit standard right hand thread and 8 10 and 14 mm bits are available as an option tp Spindle WARNING To reduce the risk of injury from contact ak with a moving mortising bit always unplug the tool before changing mortising bits or removing the fence body from the motor housing Da 1 Using the provided 12mm wrench pry up on the fence Q body release lever and slide the fence body off the motor housing The inset photograph on page 6 shows the fence body and motor housing when separated Fence Body Release Lever is Ty 4 Insert a new mortising bit and start the threads by hand to avoid cross threading 5 Press in on the spindle lock while tightening the bit Do not over tighten the bit 6 Carefully reinstall the fence body onto the motor housing and push the fence body in until the latch clicks gt Make sure there is no sawdust inside the guide tubes hollow tubes before inserting the fence body gt Be careful not to damage the linear bearings inner sur l l face of guide tube when reinstalling the fence body If spindle from turning while you loosen the mortising bit with respect to the bearings Supplemental Owner s Manual 9 Operation Overview General Notes and Tips Because the
24. lei Iin EA Rap ee S pki E pd iaaa 2 Set the mortise slot width to the narrow setting page 8 3 With the middle line of the sight gauge lined up on the pencil line plunge a mortise slot into each piece of wood Do not use the stop pins 20 4 Join the two pieces of wood together without glue and examine the alignment of the original pencil lines If the pencil lines are not aligned loosen the two screws on the sight gauge and slide the gauge sideways as noted in the upper image Note The distance between the lines is twice the actual error When adjusting the sight gauge move it only 1 2 the distance between the lines Move Sight Move Sight Gauge Left Gauge Right Alignment OK Sight Gauge Center Line 4 f i y s zo AY 7 p y i r a n l a La S j A Ey F i JI HG oat A rl i i q T r i JA S Pe TEOOT IN Domino XL DF700 Troubleshooting Symptom Possible Causes Motor does not start Plunging action is not smooth Domino tenons are too loose Domino tenons are too tight Workpiece joints are misaligned horizontally Workpiece joints are misaligned vertically Tilted or misaligned mortise slots Workpiece joint won t close gaps between pieces Tearout or rough mortise slots Tapered mortise slot The Domino tenon fits only part way into the slot Check that the cord is properly plugged into an outlet gt Make sure the Plug i
25. look and feel of the Domino joiner may already be familiar to you or similar to other tools you may have used in the past you might be tempted to forego a basic introduction to using the tool However unlike other tools of similar look and feel the Domino machine is extremely precise in its operation For this reason it is recommended that you spend some time practicing using the Domino joiner before you begin using it for your fine woodworking projects Choosing the Right Domino Tenon Size Because the Domino system is a form of the classic mortise and tenon joinery it should follow much of the same guide lines of mortise and tenon joinery Here are some guidelines to assist you in making your choices gt When the strength of your workpieces is comparable to the strength of the Domino tenon e g general hard woods then the thickness of the Domino tenon should be Domino Tenon Placement Guidelines There are no steadfast rules on where tenons should be placed especially when they are used for alignment pur poses For edge joining boards a typical placement might be 6 to 8 inches apart However when tenons are used to strengthen a joint you might be tempted to place the tenons too close together This can actually weaken the joint by removing too much of the substrate material gt A wide mortise weakens the substrate so it is better to have several narrow mortises with uncut space in between than it is to have a si
26. ngle wide mortise with several tenons side by side gt When placing several tenons close together leave at least the thickness of a tenon between mortise holes As a general rule this means the minimum tenon spacing Should be about 8 mm to 14 mm but they can be spaced much wider When creating stacked mortises for extra thick lumber an extension of the 1 3 rule mentioned above still applies Specifically the distance between mortises and the Plug It Power Cord The Domino joiner comes equipped with a removable Plug It power cord To install the power cord insert the cord into the inlet on the tool with the key and keyway of the plug aligned with the key and keyway of the port Then twist the locking ring a full 4 turn until they lock Reverse the procedure to remove the cord Notice Failure to fully lock the plug into the recep tacle will damage both the plug and the receptacle 10 For best results observe the following tips gt Always secure the workpiece firmly gt Hold the Domino Joiner firmly by the front handle and loosely by the rear handle This keeps control of the joiner at the front without biasing the main body skewed from the fence gt Plunge the mortising bit into the workpiece with a slow and steady pace approximately 1 3 the thickness of the workpieces gt For softer woods such as pine the joint will be stronger when the tenon is 1 3 or slightly less gt
27. ns on page 9 4 Note that if your workpieces are thin you may need to offset the tenon from center as shown in the picture on page 9 5 Clamp the Captive boards flat to your workbench 6 Align the tenon position using the stop pins refer to the picture on page 11 Supplemental Owner s Manual A Fi Grasp the Domino joiner by the auxiliary handle hold it firmly down to the workpiece and slowly plunge the cutter into the edge of the workpiece Clamped Workpiece Machining the Cap Side Mortises Don t change the fence height from the previous opera tion It is used to register the mortise placement from the edge of the board If necessary install the Base Support Bracket as described on page 11 If necessary change the mortise depth setting Clamp the workpiece in a vertical position as shown When plunging grasp the Domino joiner at the Base Support Bracket and hold it firmly against the face of the workpiece WARNING To reduce the risk of injury from contact with a moving mortising bit keep hands clear of the back of the workpiece in case the mortising bit cuts all the way through the board Y SN Vertical Workpiece 15 Making Frame Joints Butt Joint Frames For larger frame stock you may be able to use the stop pins When making butt joint frames such as cabinet faceframes 10 Setting the mortise position use pencil lines to lay out the position o
28. ong Support for each of the horizontal partitions of the cabinet The simplicity of this method is that you use the carcase components for aligning the joiner Vertical Side Piece j al Setup and Machining 1 Lay the vertical side pieces on your workbench and draw lines across both left and right pieces to indicate where the shelves will be located Note that it is easier to avoid mistakes later on by drawing double lines with one line above the shelf and one line below the shelf as shown Mark the 3 Locations of the Finished Shelves 2 For reference label the top and bottom face of each shelf This is so your left and right hand mortises are referenced from the same face of each shelf 3 Working with one shelf at a time lay the shelf on top of the side piece so its edge lines up with the outside pencil line for that shelf location Note To help you remember how to position the cally between the pencil lines and then gently tip it over so it is laying flat against one pencil line Supplemental Owner s Manual shelves for mortising simply stand the shelf up verti Because the mortises are registered from the base of the Domino fixed 15 mm distance the direction that you tip the shelf either toward the top or toward the bot tom depends on how thick the shelf is Use the following guidelines gt If the shelf is thick greater than 30mm tip it down with the top side facing up gt I
29. or warm environment This is normal wood movement gt gt gt gt gt The tenons are intended to be snug fitting and may require a light tap with a mallet to insert them This is what affords such high precision for Domino tenon joinery gt The most common cause for this is that the tenons are stored in a humid environment and they have swelled from moisture absorption Store the tenons in a cool dry envi ronment Swollen tenons can be re dried by heating them to 10 to 15 degrees above ambient temperature for a short period gt The mortising bit may have been improperly sharpened or sharpened too many times Replace the bit Make sure the workpiece is securely clamped before plunging Retract the locating pins when not in use Check the calibration of the horizontal position gauge sight gauge Don t plunge the mortising bit into the work too fast This may cause the joiner to move during the plunge Make sure the friction pads on the front of the joiner are not worn damaged or missing Take care not to tilt the joiner while plunging If the mortise slots were registered from the bottom of the baseplate make sure there is no dust or debris under the joiner or workpiece Make sure the fence is properly locked at the desired height setting Inspect the fence height adjustment lock to ensure it is not broken slipping Make sure the fence is set to the correct angle e g 90 degrees Make sure to hold the
30. ortises toward the rear when locked If you install the adjust able stop pins backward the locking levers will point forward when locked and this will interfere with the workpiece If this happens remove the stop pins from the outrigger arms and turn them around To invert the stop pin loosen the clamping knob far enough to allow the rear clamp to rotate then rotate the rear clamp 180 and retighten the clamping knob The front of the stop pin assembly indicates which position is for the respec tive joiner Setup Calibration To ensure that the stop pins are centered on either side of the mortise location they can be calibrated to the Domino machine to which they are attached If the stop pins are not centered about the mortise location of the machine loosen the locking setscrew and rotate the eccentric adjuster slightly When the screw slot is vertical the eccentric is in the neutral position When the screw slot is horizontal the eccentric is in the maximum offset toward or away from the mortise position A stamped O indicates the minimum offset of the eccentric Clamping Knob Eccentric Adjuster aiy Mounting y p iA E fie YE 1 With the locking handle rotated toward the front of the joiner as shown in the upper photograph insert the mounting tab into the slot from below 2 Turn the locking lever toward the rear to lock the cross stop to the base of the joiner Rear 3 Loos
31. ous personal injury gt Use personal protective equipment Always wear eye pro tection Protective equipment such as dust mask non skid safety shoes hard hat or hearing protection used for appro priate conditions will reduce personal injuries p gt 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 gt Remove adjusting key or wrench before turning the power Power Tool Use and Care gt 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 gt 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 gt 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 A Save all warnings and instructions for future reference tools create sparks which may ignite the dust or fumes gt Keep children and bystanders away while operating a power tool Distractions can cause you to lose control gt If operating a power tool in a damp location is unavoidable use a ground fault
32. ove 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 prov ince law as limited above the foregoing express limited war ranty 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 por table 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 Also contact our Service Department at the telephone number listed above if you have any questions about warranty claim procedures 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 con travention of this document is at your own risk By acceptance of this system you hereby assume all liability consequent to Proprietary Notice All drawings and information herein are the property of Festool TTS Tooltechnic Systems AG amp Co KG All unauthorized use and reprodu
33. r new Domino joiner make sure you fully read and understand all of the precautions and safety information presented in this manual A 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 AN 2 Peel off the protective film from the bottom of the joiner baseplate 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 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 3 Set up the joiner for the appropriate type of operation as described throughout the remainder of this section 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 16 1 Unplug the joiner for safety 2 Loosen the fence angle locking lever by rotating it coun terclockwise about turn 3 Rotate the fence face to the desired angle and tighten the locking lever Notes gt The fence has detent stops at 22 2 45 672 and 90 degrees Use the gauge pointer for setting the fence to angles other than
34. right a standard miter joint is constructed using a large Domino tenon for strength in the main joint The locking tenon is a smaller tenon The mortise for the locking tenon is milled with the joiner s plunge depth set to the full length of the tenon This mortise is typically milled after the joint is assembled but it is pos sible to mill the mortise in each piece separately Shortening a Domino Tenon s Length There may be times when you need a large Domino tenon but the length of the tenon does not fit your application It is important to firmly and safely hold the tenon while you cut it to length WARNING Never attempt to cut a Domino tenon s length without using a mechanical holder Holding the tenon with your hand poses an extremely seri ous risk of personal injury To make the simple tenon holder shown to the right mill a full depth tenon slot into the end of a board and then cut out a notch in the side of the holder This notch allows you to push the shortened tenon out of the mortise slot after it Tips for Applying Glue There are many different ways to apply glue to joints how ever how you apply glue can have an impact on the quality of the joint or the ease of assembly gt For a longer glue open time on complex assemblies apply the glue generously to the workpieces The thicker the glue the longer the time it will take to skin over see image below Excess glue can be cleaned off after completion
35. t connector is properly inserted and fully tightened gt Make sure the outlet has power Check the circuit breaker or try another outlet gt If used with a Festool dust extractor make sure the selector switch is pointing to Auto The auxiliary outlet on the dust extractor has power only when the selector is at Auto gt Inspect the power cord including extension cords for damage or missing prongs gt The motor brushes may have worn and need replacement gt Clean the linear rails and bronze bearings of the plunge slide and make sure they are properly lubricated refer to the Routine Maintenance on page 19 gt Inspect the linear bearings for damage Improper insertion of the fence body onto the motor housing can damage the linear bearings Make sure you hold the Domino joiner firmly in position at the front handle and loosely at the rear handle while plunging the mortise slot It is not uncommon for new users to experience this problem and is a matter of refining your technique for plunging mortises Plunging too fast can cause the mortise slot to be enlarged Slow down the plunge rate Make sure the mortise width setting is correct Make sure you are using the correct mortising bit for the size of the Domino tenon Check the mortising bit to ensure it is not bent or has a broken tip A bent bit will make a thicker and wider mortise slot than desired gt The Domino tenons may have shrunk in an overly dry
36. the ones listed above gt 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 Angle Angle Number o Equal Sides 3 Triangle 60 30 54 Supplemental Owner s Manual 4 Make sure that the fence height and angle locking levers are properly tightened F ie Protective Film 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 on page 10 Detent Hint If the position of the locking lever interferes with your operation you can rotate the lever after it has been tightened by slightly pulling the lever out and rotating it to a different position 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 mate rial being joined Refer to the Applications section begin ning 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 height stop Note It is not necessary to set the mortise height to GD be exactly in the center of a board Attempting to do so can be difficult and may actually lead to assembly errors It is more important
37. these operating instructions Using the Supplemental Owner s Manual 5 Functional Description The Domino DF700 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 simpli fies 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 uni form mortise in which a Domino floating tenon is inserted Name or Description Fence Body Motor Housing Auxiliary Handle D Fence Height Gauge E Fence Angle Locking Lever F Fence Angle Gauge 714 G Stop Pin Release Button 1 H HeightStop 8 I Fence Body Releaselever 9 J Depth Adjust Limit Stops 9 K Depth Adjust Slide _ _ 9 L Mortise Width Lever 8 Ri Item Name or Description Ref Page s _ M MainHande 10 N PowerSwith O Mortise Width Indicator B P Mortising Bit 2 Q Plug It Power Inlet 10 21 9 R SpindleLock S Dust Extraction Pot 1 T Fence Height Locking Lever 8 U Outrigger Mounting Slot 12 W Sight Gauge 13 14 20 Domino XL DF700 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 you
38. to always ensure that the Same surface is referenced for each workpiece Height Stop The height stop provides quick access to repeatable height settings This can be especially beneficial in applications where you need to continually change the fence height from one mortise to another such as an offset joint with a reveal between the pieces 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 Height Stop to its lowest setting when using the Height Gauge Setting the height 1 Loosen the fence height locking lever by turning it turn counterclockwise 2 To use the Height Stop a Raise the fence above the desired setting 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 mor tise width lever has two positions In the standard position the Domino tenon will fit snugly into the mortise slot In the wide position the mortise slot will be 3 mm wider than the Domino tenon NOTICE Never rotate the dial during a plunging operation This can bend or break the mortising bit and can also damage the machine 13 5mm 16 5mm Ln a i Bit Diameter b Slide the stop in or out until the desired setting in mm is shown in the win
39. to operate the power tool Power tools are dangerous in the hands of untrained users gt 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 Domino XL DF700 poorly maintained power tools dance 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 gt 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 accor gt To reduce the risk of serious injury never alter or misuse the power tool Service gt Have your power tool serviced by a qualified repair person the safety of the power tool is maintained using only identical replacement parts This will ensure that Specific Safety Rules for Tenon Joiners gt Mortising bits must be rated for at least the speed recom mortising bits can cause the tool to lurch sideways unexpect mended on the tool Mortising bits running over rated speed edly and lead to a loss of control of the power tool can fly apart and cause injury gt Do not operate the tool if the spring loaded fence does not gt Always use the
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