Flex Rotary Problem...Ruined My Friday! - Page 2

KaPow · 09-29-09, 01:01

You know, if you hadn't have said it, my first comment would have been... bet you're working on German paint!!

What size pads have you got? The 3403 is my favourite polisher but it doesn't have the wattage and torque to work tough paint with large pads. Move down to smaller pads and see if gets easier. The machine shouldn't start to heat up as much.

Make sure the paint is clayed first as well (I'm sure you did) and work more smoothly. Also ensure the pad is dead-centred. The reason I say this is that these are other factors that will cause your polisher to strain and labour on the paint.

When there is not enough torque and wattage to support the pad, polish and paint types then the carbon brushes in your machine are going to wear down and the machine will start to cut out.

If you want to work on German paint, then the Flex 602VR is your machine. Otherwise you will be working the paint all day long and making slow progress.

So either smaller pads or bigger machine -your choice!
Problem is though, your new machine may have worn brushes on it now so they might need to be replaced. You got a service centre near you?

bwalker25 · 09-29-09, 06:23

Quote:

Originally Posted by KaPow

You know, if you hadn't have said it, my first comment would have been... bet you're working on German paint!!

What size pads have you got? The 3403 is my favourite polisher but it doesn't have the wattage and torque to work tough paint with large pads. Move down to smaller pads and see if gets easier. The machine shouldn't start to heat up as much.

Make sure the paint is clayed first as well (I'm sure you did) and work more smoothly. Also ensure the pad is dead-centred. The reason I say this is that these are other factors that will cause your polisher to strain and labour on the paint.

When there is not enough torque and wattage to support the pad, polish and paint types then the carbon brushes in your machine are going to wear down and the machine will start to cut out.

If you want to work on German paint, then the Flex 602VR is your machine. Otherwise you will be working the paint all day long and making slow progress.

So either smaller pads or bigger machine -your choice!
Problem is though, your new machine may have worn brushes on it now so they might need to be replaced. You got a service centre near you?

Just curious what you based that comment on?

Perhaps knowing the specs of the flex 3403 would help out instead of assuming the flex didn't have the "balls" if you will. Below is a link to Flex NA and the specs are copy and pasted directly from there site:

Quote:

Originally Posted by below link

SPECIFICATIONS

L 3403 VRG

Max. polishing pad diameter 6-1/2"

Max. back-up pad diameter 6-1/2"
Tool fixture 5/8-11.
Speed without load 1100-3700 RPM
Power input 11.5 AMP
Power Output 1400 w
Weight 4.85 lbs

Welcome to FLEX North America

The interesting thing is that the power input is 11.5 AMP and the power out is 1400 watt, why is this important you ask? We all would agree that the Dewalt Polisher DW849 is a top quality polisher and a true work horse. So again why would the above WATT and AMP specs matter? Here is your answer:

Quote:

Originally Posted by dewalt usa dw849 product page

Amps 8.0 AC Amps
Max Watts Out 1,400 W
No Load Speed 0-1,000/0-3,000 rpm
Spindle Thread 5/8"-11
Spindle Lock Yes
Tool Length 17.3 "
Tool Weight 8.25 lbs

DEWALT DW849 : 7"/9" Electronic Variable Speed Polisher

Both machines have the same specs as far as output watts, and the flex pulls more in terms of amps than the DW849 does.

Yes it is possible that the flex would over heat with extremely large pads, but I dont see that being a big threat or reason it would over heat.

Now the power cord could be loose, or something else going on inside to small of an extension cord run over to long of a distance could be an issue as well, but to say the flex doesn't have the "balls" is completely incorrect.

But we all know you can't compare performance based on "Amps" and "Watts", yes the stronger motor in the flex could cause an overheating issue in the "smaller" housing that the lightweight flex uses vs. the larger oversized housing the DW849 uses.

Setec Astronomy · 09-29-09, 06:42

Quote:

Originally Posted by bwalker25

Both machines have the same specs as far as output watts, and the flex pulls more in terms of amps than the DW849 does.

Pretty hard to dissipate 1400W with only 8 amps at 115V, or even with 11.5 amps....Ohm's Law, you know?

All these Flex stories consternate me a bit...I have both a 3401 and a 3403, and I don't have much time on either, but they've both done what I needed them to do. But it sure seems like they need to research their gear cuts or lube or something.

bwalker25 · 09-29-09, 06:49

I have to say my flex will get WARM but it by no means gets hot and I use a 50 ft drop cord. I have heard the flex rotary has a break in period, dont remember where I read that at but some how 50 hours rings a bell with me.

FWIW I use the Edge wool pads and the LC 6.5" pads with my flex and never had a big over heating problem.

Setec Astronomy · 09-29-09, 07:02

Quote:

Originally Posted by bwalker25

I have heard the flex rotary has a break in period, dont remember where I read that at but some how 50 hours rings a bell with me.

Holy crap I'll be dead before I get 50 hours on my 3403.

getcha · 09-29-09, 07:02

My Flex 3403 rotary gets HOT as well after about 10 minutes use. Cant even touch it.

Also when any pad is in contact with the surface it gets a knocking sound that increases right along with RPM. You can hear near the top third of the machine meaning from cord to bail handle as the top reference.

The other thing is that with this knock noise comes a slight dimming of any halogens I'm using it with. My makita does not do this at all. With the makita when speed is bumped up it dims but then recovers back. With the flex its like a small little disco show. Its quite annoying.

For the warranty issue gurus: is there a way to get shipping covered as well. My flex is newish and I really dont want to spend money on something that isnt my defect.

jphilbeck · 09-29-09, 07:14

I am using 6.5 inch pads so they are definitely not too big. Like I said earlier, bought a new contractor 50ft extension cord so that isn't it either and the pad is centered. I always clay any car I am buffing. When I got the first 3403 I buffed a Lexus with no problem and actually buffed my M3 with no problem. Today I was working on a Chrysler so not hard German paint. Also, ran my Flex 3401 for a few hours today and no overheating at all.

getch may be on to something. Mine makes the same knocking noise right along with the RPM. The replacement one I received today seemed worse than the other one and actually didn't seem to run as smoothly. Had more of a vibration even with just the backing plate on and running with no pad in the air (was checking to see if it was going to overheat). However, I don't have any kind of lighting issue so no disco for me! Anyway, AG is shipping me another one and these two I have are going to Powerhouse to see if there is an issue.

As far as warranty, the shipping is covered.

getcha · 09-29-09, 07:20

How did you do it with Powerhouse? The gentleman I spoke to made it sound like shipping was on me

Setec Astronomy · 09-29-09, 07:22

I'm going to say this sounds like a QC problem like the 3401's where the gears weren't being lubricated properly. Sound like a gear clearance problem on these 3403's.

KaPow · 09-30-09, 11:53

Quote:

Originally Posted by bwalker25

Just curious what you based that comment on?

Perhaps knowing the specs of the flex 3403 would help out instead of assuming the flex didn't have the "balls" if you will. Below is a link to Flex NA and the specs are copy and pasted directly from there site:

The interesting thing is that the power input is 11.5 AMP and the power out is 1400 watt, why is this important you ask? We all would agree that the Dewalt Polisher DW849 is a top quality polisher and a true work horse. So again why would the above WATT and AMP specs matter? Here is your answer:

Both machines have the same specs as far as output watts, and the flex pulls more in terms of amps than the DW849 does.

Yes it is possible that the flex would over heat with extremely large pads, but I dont see that being a big threat or reason it would over heat.

Now the power cord could be loose, or something else going on inside to small of an extension cord run over to long of a distance could be an issue as well, but to say the flex doesn't have the "balls" is completely incorrect.

But we all know you can't compare performance based on "Amps" and "Watts", yes the stronger motor in the flex could cause an overheating issue in the "smaller" housing that the lightweight flex uses vs. the larger oversized housing the DW849 uses.

Hi bwalker & gang.
Yeah, I'm very aware of the technical specs and try to avoid assumption. It can't be helped when trying to offer friendly solutions based on limited information though.

I'm using Flex machines for about 10 years now and prefer them for a lot of reasons. My comments were based on personal experience as well and I was going on the information given. Thanks for analysing my suggestion though.... its making for more interesting input and possible solutions for jphilbeck. .

I will gladly put my hands up and admit to offering only layman suggestions. If anyone with electronics experience can help, please jump in!

Now that pad size used has been clarified, I'm inclined to agree with Setec Astronomy that there may be a production issue with the current batch. I use much the same pads, although I find CG Hex Logic causes my machine to heat more than LC or 3M. I don't think the issue is with the input from the cable because the problem specifically occurs at level 2. Its still a low speed, which is why I was concerned about the pads, paint, etc. and the amount of stress put on the motor.

Quick question for jphilbeck.... is it cutting out when you are working only or can you hold the machine free and put the speed way up? Either way, I hope you get your polisher going well soon! I'd be lost without mine.
C ya later.
KP.

RustyBumper · 09-30-09, 03:42

Quote:

Originally Posted by Setec Astronomy

Holy crap I'll be dead before I get 50 hours on my 3403.

Setec-Will you leave it to me in your will?

I'm sorry to hear that you're having problems with your rotary, jphilbeck. I hope that you get this issue resolved quickly.

Thanks for posting this. I've read lately that a lot of people are having problems with their Flex machines, including myself. My 3401 is starting to make some odd clicking sounds when polishing. It just started doing it, so sometime this week I'm going to lube the felt ring with air tool oil and see if that helps. I was thinking about getting a Flex rotary, however I'm having second thoughts and am starting to lean towards the Makita.

Best of luck to you, amigo.

jphilbeck · 09-30-09, 06:14

Thanks for the support guys and helpful suggestions. First, I am using the LC CCS pads and new Hydro Tech pads (already stated they are 6.5 inches). It is only cutting out while working. I have tried just spinning it without touching anything and it still heated up but seemed normal to me. I would still highly recommend the Flex products to anyone and love them. I actually used my 3401 today to cut a truck and forgot how much I loved it. I have had no issues with it whatsoever and it does not overheat at all.

I still love the 3403 because the size and weight are just perfect for me. I just wish I could get one that works properly!!! Who knows??? We will see.