On again and off again router

pmallett | Posted in General Discussion on October 6, 2003 04:21am

I was hoping someone out there might be able to help me. Yesterday I was cutting some dovetails using a jig and router and my Dewalt 621 router started cutting out as if the power was switching off. I would let go of the switch for a second, and re-depress the switch again, and it would start again, fully power up, and run for about 1-2 seconds, and power down again. I felt no appreciable heat from the motor, and checked and rechecked my cord connections to no avail. This machine is about 2 years old, but I bet I don’t have 10 hours on the dern thing. Any ideas out there?

Pat

Replies

BG | Oct 06, 2003 04:34pm | #1
Pat,

I had the same problem with my 621 and brought it back to Woodcraft. They gave me a new 621 ....and the problem still kept happening. I was told that if there is a drop in power it will cut out.....I was told that if I giggled my finger it would cut out...

I put it on a seperate line....stopped giggling..it worked better...but from time to time it cut out. Now I have it in the router table with the switch taped in the down position....and it does not cut out. I have it pluged into a power strip along with the vac and they both turn on when I throw the power switch....

I can only conclude my problem was the giggling...

pmallett | Oct 06, 2003 07:09pm | #3
BG:

Thanks for your response. I'm going to check my extension cord, it might be too small/long and am having a power drop. Checked with my local DW repair shop, and national as well. They don't have any special bulletins out on this product showing this happening often. However, if I can't get this working properly, It will probably cost me about 100 bucks for repair. That doesn't make me real happy considering the very low hours I have on it. Might think about just getting a Porter Cable or something if this is the best this DW holds up. Once again, thanks.

Pat

Len | Oct 06, 2003 05:17pm | #2
You might try checking on the Dewalt site.

http://www.dewalt.com

I had a question about a tool that wasn't working and they were very quick to answer and find a solution.

Enjoy,

Len

pmallett | Oct 06, 2003 07:11pm | #4
Len:

Thanks for the website, I didn't hear anything from them that I really liked, but it gave me a source that I could vent.

Pat

Elcoholic | Oct 06, 2003 11:35pm | #5
My DW 614 Switch has failed to shut-off a couple of times due to dust buildup which is easily cured with a blast of compressed air. I've never had any trouble with the switch on my DW625 which has only been out of the router table 2 or 3 times. I don't have a D621 so I can't say for sure. I do have a bitch about DW tools in general though. They must use the absolute cheapest cords on the market. The jackets crack and fall apart way before they should.John O'Connell - JKO Handcrafted Woodworking

Life is tough. It's tougher if you're stupid - John Wayne

pmallett | Oct 07, 2003 12:11am | #6
John:

Thanks for responding. I checked everything I could, blew compressed air, did away with an extension cord finally gave up. I took the machine to DW repair here in town. Treated rudely, but did my best to not lose it. I'll find out in 5-7 days what the problem is. My biggest gripe is that this machine has so few hours on it, been treated with kid gloves. I read the archives here on knots to see if anyone else had had this problem. I found alot of people really like this router. Maybe it's just a fluke. Once again, thanks

Pat

Buglehead | Oct 09, 2003 08:07am | #8
Pat,

Go on over to Breaktime (Taunton's Fine Homebuilding site) and do a search on "yellow crap." You will find that those users have had lots of problems with quality, and especially switches. HTH.

Bill

Jamie_Buxton | Oct 07, 2003 04:14am | #7
Two possible causes: the power switch is flaky, or the electronics module is flaky.

If you're comfortable probing around inside tools, you can get to the DW621 power switch without too much difficulty. Remove the knob with the trigger in it, and the cover behind it.

I don't know of any way of testing the electronics module except by replacing it. It, too, is pretty easy to reach -- but you have to acquire a module to use in the test.
RANGERP75R | Oct 09, 2003 08:22am | #9
Pat

Have to agree with Jamie and Buglehead. It sounds like a switch from what both you and BG described. I have a 621, but have only logged about an hour on it. I have 5 routers and use it strickly for free-hand plunge. Great for that, but from the fragility of the switch, I expect it to fail. I just don't know when. ha..ha..

Good luck...

sarge..jt
dirtstirrer | Oct 09, 2003 02:32pm | #10
Pat,

I had the exact problem with my 621. I sent it to a service center, new switch, and bingo.

Mine has developed a new quirk, I wonder if yours is showing these symptoms too. On a long cut, the RPM's vary a little. Maybe a 100 RPM or so. Not enough to be a problem, but makes you wonder what's going on.

aka Steve
ETG | Oct 09, 2003 02:32pm | #11
I live in the shadows of Black & Decker and their DeWalt branded product's corporate headquarters and product development. A brief story may give some insight into your problem:

A good friend is a manufacturing rep and he has provided switches, led's, etc. for Black & Decker's former plant in Easton Maryland. One day he was called in by the purchasing agent and told an off shore vendor was providing components at half my friend's price. My friend picked up some samples of the half price components and had them tested. They did not meet B&D's Engineering Spec. When told about this, the purchasing agent said that was Engineering and Quality Assurance's problem - he just buys on price. And it's not unusual to see employment "opportunities" at B&D for Engineering and QA positions - year after year after year.

In my area, we say "friends don't let friends buy DeWalt (the branded tools - the old radial saws are a different story, particularly pre B&D). You won't find DeWalt in the production shops in my area - they know better!

Edited 10/9/2003 9:01:35 AM ET by EDGREGG