Originally Posted by Dekker

No, not woodworking help, but electrical help! First the story, then the question...

I have an FT2000e that I have kept table-mounted for a couple years now. I was using it yesterday (table mounted) to rout edges on a series of panels and as I was switching panels, I heard the router give a "warble". I quickly reached for the power switch and switched it off. I had an experience once of a router bit moving vertically, and I had a nightmare of my bit having come loose and about to fly free, but I'm glad to say it was not that...

So I look things over, everything looks fine, the bit is still firmly attached, so I flip the switch back on: NOTHING.

The sound I had heard can be best described as the sound a Formula-1 car makes when its RPMs are restricted by its engine limiter, like the router was not firing on all cylinders.

I took the thing apart, blew out the dust, tested again, but no luck. I then got out my volt-meter, and did some continuity-probing (without being plugged in), and everything "looks" OK, with two exceptions... The variable-speed control is not showing any continuity between the in-and-out leads (of course, with no power applied). Secondly, one of the brushes has an edge missing.

Questions:
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So my real question is, does anyone know whether the speed-control should have continuity with no voltage, or only with voltage?

And secondly, would that small chip in the brush cause the failure to start? Any way to test/eliminate that as a possibility? I'm reasonably competent electrically, but without knowing what appropriate values are, I can't self-diagnose it...

And finally, does anyone have a service-manual for the router, or is the assembly diagram the best/only information available?

Yes, a long post, but thought I'd be thorough

Originally Posted by Dekker

Well, it's been a few weeks, and here's the update. (Thanks for all the suggestions everyone!)

I brought it to a shop and the tech agreed with my prognosis. So I ordered a replacement speed controller for the router (95$). A week and a bit later I get the call that it has come in, and discover it is the wrong part! Well, not quite. The one I needed was part number xx15, they sent xx16, which is the replacement for the 15, but newer. They were nice enough to include some instructions and a couple small parts to convert my existing router to handle the new controller.

BUT, the last line in the instructions read: If your router does not have the threaded shaft, you will need to replace the armature as well.

WHAT!!?? Of course, mine is not threaded, and so I'm looking at another $125? to replace the armature of the router (the main body that spins...) With that investment (225) I may as well consider replacing the router!

So for now I left the part at the shop, and am window shopping for a new router. I need one ASAP to finish the project I'm in the middle of. I'll probably keep my eye out for pawn shop duds and classifieds for a used/dead Freud FT2000 so I can steal its controller (my router body is pristine!).

I'm somewhat disappointed in Freud though, to not continue offering the existing part. I'd pay the same $95 to get the same old controller, even knowing that it might die in another 2-3 years. I just can't justify spending over 200 for parts that will get me 90 days warranty, when a brand new one is 350 with 5 years.

Now I'm going to have to look at other brands again, but this time I'll be keeping a better eye on the repairability of the router! Oh well, yet another review to add to my blogs!