Replies

1. 
   JohnWW | Jul 10, 2006 06:46pm | #1

   Mike,

   Two good possibilities:

   1. The symptoms sound like the speed control failing but first check the brushes.  Most brushes have a mark on them to show the wear limit.  The brushes probably started out around 3/4" long.  If they're down to 3/8" or so, or are close to the wear mark, or if the mark is gone, the brushes need to be replaced.  They also need to be replaced if they are burnt and crumbling or if the copper pigtail to the brush is damaged, loose, or burnt off.  If the brushes are good, then the second possibility is the most likely cause.

   2.  The speed control is failing, which can generate any number of erratic symptoms similar to what you are describing.  Often the controls will act up when they get very hot and will be fine when they have cooled off, which would also match your experience.  If dust blocked cooling air from reaching the module, which can get blazing hot under a heavy load, that may have caused the overheating and the malfunction.  It is possible that you haven't done any permanent damage to the control if it just overheated from lack of cooling, but it is more likely that the part is failing and will have to be replaced.  On most routers replacing the control is a fairly simple job.

   John White, Shop Manger, Fine Woodworking Magazine

1. 
   mudman | Jul 11, 2006 04:16am | #6

   Thanks John,

   I think that you are likely on to something. I thought that I burned out the speed control completely when it happened the first time, but after restarting it ran correctly.The router does get very hot. I keep the cabinet open and have a box fan blowing from behind me into the cabinet, but it still gets hot enough that I can't leave my finger on the motor housing. I have a profesional shop and I think that I am stretching the limits of a router table set up. Pardon my spelling,

   Mike

   Make sure that your next project is beyond your skill and requires tools you don't have. You won't regret it.

2. 
   Knotscott | Jul 10, 2006 06:55pm | #2

   I have no where near the knowledge that John and others have, but the first thing I'd do is to blow out any dust just as a basic maintenance step. MDF has extremely fine silt.

3. 
   bones | Jul 10, 2006 08:29pm | #3

   I have not seen this behavior in mine, but then I have not tried that heavy a cut. This may sound to simplistic, but try calling the tech services line.  

   Service Centers/Technical Information: (888) 848-5175

1. 
   Knotscott | Jul 10, 2006 09:11pm | #4

   Call the tech line?! That is way too easy. Surely there must be more complicated fixes....Friends don't let friends call the help line! LOL!... ;-)

1. 
   bones | Jul 10, 2006 10:11pm | #5

   I know I broke the man-code sorry.  Thirty lashes with a wet noodle.

2. 
   mudman | Jul 11, 2006 04:19am | #8

   You got it Scott. I have never been able to get the tech guys to argue wuth me about some assinine detail. So I prefer to bring my delimas to this valuable forum where I can recieve knowlage and experience whos depth has no limit.

   heh hehPardon my spelling,

   Mike

   Make sure that your next project is beyond your skill and requires tools you don't have. You won't regret it.

4. 
   Routerman | Jul 11, 2006 04:18am | #7

   A pity; the toughest router around, and with a brain handicap! Indeed PC 7518 controllers do exactly as you describe.

   If it gets critical the machine can be converted to a single speed. Have several of these tools over many production runs; they all have micro-processor problems. Air blow can help.

   When they run they are to be respected as they are toughest of all 3 HP tools.

   Routers