Router kit recommendation (my DW618 died) - Router Forums
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post #1 of 21 (permalink) Old 01-08-2010, 01:10 PM Thread Starter
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Default Router kit recommendation (my DW618 died)

Hello.. I am, or was, the owner of a Dewalt DW618 kit (fixed & plunge base). I really liked this router a lot, it's a great tool. But- this week the motor burned out. Now, I am not a contractor, this router has not seen heavy use, and mostly with softwoods like pine. I understand things can happen but- I did some web searching and found numerous postings about the same motor burnout problem with the DW618. Of course its just after the 3 year warrranty expired and repair will cost as much or more than a new router. Pretty upset about this and I wrote Dewalt.

So- I'm in the market for a new combo kit, not Dewalt. Looking at the Bosch 1617evspk, Milwaukee 5616, & Porter Cable 893pk. Since I had this experience, I thought I'd make this posting and see what thoughts you folks have on the subject.

Thanks!
Jack
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post #2 of 21 (permalink) Old 01-08-2010, 02:24 PM Thread Starter
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..while we're on the subject- maybe there's a way to fix this Dewalt motor?
I was routing, suddenly i there was a slight burning smell, the motor slowed down and stopped. Now if I try to power it on, I hear a very quiet sound - it sounds like crickets...
Is this the bearings, the brushes, both? Is this difficult to repair?
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post #3 of 21 (permalink) Old 01-08-2010, 06:11 PM
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Hi Jack:

Turn the shaft by hand. If it rotates freely, then the bearings should be okay. (Remember to turn in the same direction that the motor would naturally turn.)

If the shaft doesn't turn freely, then there are a host of possibilities. This include, but not limited to,:
1. Bearing(s) seizing.
2. The rotor is binding on the stator. (For those less into this: the rotor is the rotating part and the stator is the stationary part.)
3. The brushes may be shot or "missing." ("Missing" referring to the brushes having come out of their holders.)

The burning smell can come a number of sources, including:
1. Bad brushes.
2. Bad commutator (the place where the brushes run against.)
3. Breakdown of the insulation on the wires in the motor.
4. Friction on contaminants between the rotor and the stator.
5. Bad bearings. (I don't believe that bad bearings would be the culprit.)

If one is mechanically inclined with regards to motors, one could remove the rotor and inspect for the above items.

Repairs:
1. If the windings haven't burned, then proceed to below. Otherwise, either have the motor unit rewound or scrap the motor unit.
2. If bad bearings, just buy a new set and do the repair.
3. If bad brushes, just buy a new set and install.
4. If foreign body (e.g. sawdust) is trapped between the rotor and stator, remove the foreign body.

I highly recommend the Bosch 1617EVSPK kit. Mine has given good service.

Hope this helps,
Cassandra

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post #4 of 21 (permalink) Old 01-08-2010, 06:30 PM
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To add to Cassandra's input it could also be the trigger. If it's a VS it could be the rheostat. Sometimes the burning smell is from the coating on the wiring melting the plastic, if it melts onto the rheostat it kills the circuit.

It happened to my old Craftsman recip saw. Once I had a new PC I savaged the Craftsman to see what it looked like inside, saw the melt, scraped it off and it ran, then died a couple weeks later.

I used to use 8" Skill circs, they had a bad habit of cooking triggers, so often that I had extras.

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post #5 of 21 (permalink) Old 01-10-2010, 06:02 PM
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You could always buy just the 618 motor or the router with the base. Never hurts to have the extra base around.
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post #6 of 21 (permalink) Old 01-10-2010, 07:09 PM Thread Starter
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Quote:
Originally Posted by Twill57 View Post
You could always buy just the 618 motor or the router with the base. Never hurts to have the extra base around.
At this pont I don't think I'd throw money at another Dewalt. Replacing just the motor is $160 and there are too many people reporting the same problem of the motor burning out. Shame though- I have perfectly good bases, and an edge guide.
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post #7 of 21 (permalink) Old 01-11-2010, 06:04 AM
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So sorry to hear of your tragic loss. I am thinking it's a cooked rheostat or brushes, too. That is disappointing. I looked into an extra motor, as I have the 3-base kit, and would like to have 2 motors and 3 bases. The cost was pretty out of line, not much less at all than buying the single base 618.

As for what to get if you replace rather than repair- when I was trying to decide, I was having a helluva time deciding between the Bosch and the DeWalt kits. I like certain features of each better than the other. So if my 618 hung me out to dry I'd hop on the Bosch. I like the elevation controls, and of course those wooden knobs are pretty sexy.

The squat stance of the 618 was very appealing to me versus the taller Bosch.

Buy the Bosch kit AND fix the 618!

Edit: I missed the comment about "crickets". That sounds a lot like brushes to me. They are pretty easy to replace if that is the case. Be sure to blow the old carbon out with a very dry airline before installing new brushes. You definitely do not want to do this indoors though. Envision a small black cloud...

Last edited by voodoochile; 01-11-2010 at 06:11 AM. Reason: added repair note
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post #8 of 21 (permalink) Old 01-11-2010, 06:20 AM
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Take a look at the Sears offerings. Really nice routers.

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post #9 of 21 (permalink) Old 01-11-2010, 08:45 AM Thread Starter
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The Bosch 1617- all these reports of the switch failing.. is that something Bosch has resolved with what's being currently being sold or is it still a problem?
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post #10 of 21 (permalink) Old 01-11-2010, 08:49 AM Thread Starter
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Quote:
Originally Posted by voodoochile View Post
Edit: I missed the comment about "crickets". That sounds a lot like brushes to me. They are pretty easy to replace if that is the case. Be sure to blow the old carbon out with a very dry airline before installing new brushes. You definitely do not want to do this indoors though. Envision a small black cloud...
An update on the "cricket" sound. I plugged it in yesterday and there is no more cricket sound. There is only SILENCE.
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