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Discussion Starter #1
Hi, folks. I would be happy to take this to a professional, but they are all hundreds (thousands?) of miles away, and I need this now, of course.

My Hitachi M12v is about 4 years old (I purchased it from Amazon.com). It has occasionally not operated when the switch was turned on, but I guessed that the motor had stopped where the brushes were not making electrical contact, and a moderate thump on the side or sometimes turning the bit by hand (with the switch off, of course), always got it going again.

The last week it had been doing this much more frequently, but it always came around quickly until yesterday, when it just coasted to a stop in the middle of routing an edge on some pine. I wasn't taking a very big bite, either (low load).

I checked the power and flipped the switch a couple of times, and at first it would make literally a couple of revolutions and then remain remain stationary. Now it is totally dead.

The household power supply if fine The brushes are like new. There is no sign of any damage to the cord or plug. The main shaft turns freely. The motor was not overly hot.

I must confess to having banged it a bit, not because of it not starting, but because it was sticking in the up position (it is table mounted, and I just installed a lever-type lift assist device), and I was lifting it and letting it drop to get it up-stuck -- this is WITH the springs installed.

My best guess is that a connection in its internal power circuit has come loose. My plan was to open it up to see if I could find a a wire to reconnect, as I have successfully done with a belt sander and a jigsaw when they each just stopped working. The case appears to open via four smallish Phillips-head screws on the bit-end of the assembly.

The immediate problem is that those little %&*^(&*(*@&(*A&(*#(*$# screws will NOT budge. It would seem that Hitachi wants to be the only one examining its innards. Any suggestions?
 

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Take a small soldering iron - 25-45 watts and heat the machine srew head up until quite warm, and then try and loosen the screw. This will soften any thread locker used during assembly. If tapped intop plastic, be careful not to overheat the screw and melt the plastic.
 

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Merri, we ask you to fill out your profile so we can better assist you. Where are you located?
 

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Discussion Starter #5
Thanks for the suggestions -- I'll give them a try ASAP. I got that project done by borrowing a router from a neighbor, but now want to get my own setup working again.

I will edit my profile as requested/reminded (thank you), but FYI in the meantime, I'm in Los Alamos, New Mexico.
 
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