[Mike]

You said there was a lot of saw dust that came from the inside of the housing... and I believe this is the cause of your overheating/thermal shutdown. You may need to take this unit apart to get ALL the dust and debris out of it. It would not surprize me that your brushes were ready to be changed. The easiest way to be sure is to look at a new pair and see how much is worn away. It is also possible that you have one or more bearings close to failure, and that is a sure cause of over heating. This type of troubleshooting and maintenance is best done by a professional, so unless you are 100% sure of yourself take it to the service center.

 

[Mike]

Terry, let us know what you decide to do. This is just a thought but... isn't it possible to bypass the speed control and run strictly by way of the power switch? This might put your router back into service with no cost.