Mr White, I’m having trouble with one of my routers, a Freud used in a router table. I have to flip the switch a couple of times to get it started. Sometimes it will start on one try. However, the motor often drops in speed (electronic speed control) with no load. It seems to hold speed better if I lower the rpm dial. The brushes don’t look too worn but I know I’ve got alot of run time on it. One of the brush wires is a little frayed. If it’s more than brush/switch, I’ll opt to replace the router. Any ideas?
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Replies
I'd start by replacing the brushes, they shouldn't cost much, and they can certainly cause the erratic starting problem you described. They could also possibly lead to speed control problems depending on the design of the speed control module. The frayed wire could be a result of the brushes having worn down to the point that the wire is rubbing on the brush housing.
I'm more inclined to suspect that a failing variable speed switch is responsible for the speed control problem, and a failing switch could possibly cause the erratic starting, but I'd replace the brushes first as an economical first step to tracking down the problem. If the new brushes don't solve the problem then it is a pretty safe bet that the switch is failing.
John White
Thanks much. BTW, I always enjoy your articles...we can have passion for the tools too right?!
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