deWalt DW 621- dead. - Router Forums
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post #1 of 52 (permalink) Old 12-10-2015, 09:16 AM Thread Starter
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Default deWalt DW 621- dead.

Hi- my lovely trusty DW 621 has suddenly stopped working. I managed to get it going infrequently by a firm tap on either side with a hammer (where I thought brushes likely reside). So this implied -possibly- was indeed brushes, an easy fix. But now its totally dead, not even a fraction of a second working at all.

Brushes out & certainly don't look new, being maybe 1/3rd of length of new ones, one maybe even 1/4 as long.. but the springs clamp them both (call them 1cm left of the graphite block each) still firmly it seems against armature & I can see them rubbing when I twist the spindle ok.

Any ideas? Thanks M. Snake.
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post #2 of 52 (permalink) Old 12-10-2015, 09:19 AM
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Dirty/dusty switch...?

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post #3 of 52 (permalink) Old 12-10-2015, 10:51 AM
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Switch is a good possibility like Nick says. It's an easy test if you know a bit like it sounds you do. Just put a jumper across the in and out wires on it and see if it fires up.

Someone I consider a master woodworker once told me that a master woodworker is not someone who never makes mistakes. He is someone who is able to cover them up so that no one can tell.
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post #4 of 52 (permalink) Old 12-10-2015, 05:58 PM
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If Charles idea doesn't work,look at the brushes.

Intermittent running sounds like brushes to me,Especially if you can tip it or bump it and it will try to start.

Herb
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post #5 of 52 (permalink) Old 12-10-2015, 06:21 PM
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Just a question for my future learning---if it is brushes, which means that it's been used enough to wear the brushes that far, might it make sense to pull and clean the armeture? If so, bearings replacement while it's apart?? Or is just putting a set of brushes in a normal practice??

Thanks!!
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post #6 of 52 (permalink) Old 12-10-2015, 10:08 PM
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Definitely agree (over use) with GreenA. Machine due for replacement or gross overhaul.
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post #7 of 52 (permalink) Old 12-10-2015, 10:10 PM
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Quote:
Originally Posted by greenacres2 View Post
Just a question for my future learning---if it is brushes, which means that it's been used enough to wear the brushes that far, might it make sense to pull and clean the armeture? If so, bearings replacement while it's apart?? Or is just putting a set of brushes in a normal practice??

Thanks!!
earl
go w/ the normal...
Attached Files
File Type: pdf Diagnosing Electric Power Tools 101.pdf (386.8 KB, 104 views)
File Type: pdf Is it the Brushes or the Switch.pdf (182.5 KB, 89 views)
File Type: pdf Maintenance and Troubleshooting of Electric Motors.pdf (68.0 KB, 118 views)
File Type: pdf How to METER test electric motors.pdf (217.2 KB, 121 views)
File Type: pdf TESTING armature windings.pdf (100.0 KB, 107 views)
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post #8 of 52 (permalink) Old 12-10-2015, 10:12 PM
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If you can find the right supplier bearings are fairly cheap, as in about $10 each.

Someone I consider a master woodworker once told me that a master woodworker is not someone who never makes mistakes. He is someone who is able to cover them up so that no one can tell.
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post #9 of 52 (permalink) Old 12-11-2015, 08:58 AM
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Default Not Recommended Brush Test

I was given a Makita drill that didn't work properly... slow, intermittent and gutless. I didn't know if it was worth investing in parts. Thinking it might just be brushes, I carved a couple of brush 'extensions' out of carpenters pencil lead. This added about about an eighth of an inch to the length of the brushes. When this improved the performance, I knew it was the brushes. It turned out that the brushes only cost the equivalent of two large coffees anyway. Had I known that I could've just bought the brushes and saved myself some work.

When I replaced the brushes I also carefully cleaned the comm up a bit with sandpaper and blew out the crap. The drill works like new now... my most-used corded drill.

Moral: If you suspect the brushes and they're cheap, just buy a set and try it.
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post #10 of 52 (permalink) Old 12-14-2015, 04:06 AM Thread Starter
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Hi chaps- thanks for replies, only just aware of them all. Grateful.

Now I checked switch- fine, and am quizzing the brushes as one might. Ive orddered some (had to instigate the most likely parts on their way/ I make a living with this router, but cant afford a deWalt service, and Ive repalced brushes on a cheaper router before with ~ similar'ish symtoms) so fingers crossed just that.

But it might be the control unit (is the other fallible part of these dw621 routers, from www spiel afaict). Some folks mentioned you can test this by bypassing it with a couple of appropriate wires.. but without knowing exactly what Im doing/ which wires to connect to bypass Im not proceeding.. unless with help here. Its a simple thing to do sure, but one that could kill the router if I apply wrong.

Anyone bypassed a control unit before?
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