I went down to turn on my machine this morning to finish a project. Hit run on Control and the machine started moving but the router didn't spin up. Lights on router turned on but no rotation. 3rd time this has happened with the Dewalt 611. First two times I replaced the router, don't know what to do this time. Router has about 30hrs on it so it shouldn't (?) be the brushes already? I don't think I can just take this one back and replace it. I guess ill take it apart and try to blow any dust out of it. Any thoughts on why this is happening so frequently? Something um doing, not doing? Beyond frustrated! Should I bag the 611 and go with something else? I can't have this happening all the time. Any thoughts?
Checking brushes would be the first thing, though its a bit low on the hours. Are you running it quite aggressively? From our (and my personal own) experience the DWP611 is quite resilient
I ran a project that took about 3 hours yesterday. I don't feel like I'm running it that hard but I guess its possible. What should I be looking for on the brushes?
I meant in terms of tooling diameter - running some 1 inch router bits with a 6.35mm shank? Or running standard endmills. Speed - router always dialed to speed max or running at like 3-4 depth of cut - full depth or recommended half of endmill diameter Wood, alu, what are you cutting Ie. how aggressive is the cut itself, does the router bog down, that sort of thing. High RPM and bogging eats brushes - long hours at good cut recipes doesn't
My cuts have only been with 1/4 and 1/8 bits in wood. Other than the length of time(some cuts at 2 or 3 hours) there hasn't been any major stress on the motor. I took the brushes out and from what I see by looking at videos these are shot already? I added some pics for you to confirm. Ill replace them and see if thats the issue.
Yes those are worn, the dewalt eats brushes, order a few sets they are inexpensive. Do you run at full speed for those projects? reducing the rpm extends the life. Minimum rpm is 16000 on that router which is plenty for most jobs. Also use compressed air or canned air and blow out the brush area often, dust and heat will speed the wear. Gary
DeWalt supposedly call for maintenance at 100hrs on the DW611. That's probably at an "average" duty cycle where a mix of speeds are used. Near-max-speed continuous usage cuts the lifespan of *all* spindles- even $50,000 ones- in half or worse. Keep an eye on the bearings as well as the brushes if this is the case, because you can cook the grease right out of them.
I bought a set of 4 off Amazon. I guess I'm down for today but thats fine. Strange that nobody around here has them in stock. I haven't run that thing at full speed at all. Most of the time its at 3 or 4. Ill deal with it. They are super easy to change at least.
