How to Replace the Cord and Strain Relief on a Porter Cable Router
This article will teach you to remove and replace the cord and strain relief on your router. This easy repair will help you keep your router running in top condition and help you troubleshoot future r...
Electric Power Tool Parts 101
This article defines the basic parts of most power tools, explains how they work, and what to look for when they stop working.
Diagnosing Electric Power Tools 101
This article is a troubleshooting guide for problems and malfunctions common to most electric power tools.
Discussion
Discussion for the DeWALT DW621 TYPE 2 2HP Plunge Router
My router was working fine but suddenly it stopped. Then it would start but once it reaches speed it dies. Took off the top cap and found the armature seat to be off center. It popped off with screwdriver. Could the electronics module have failed?
I shattered part of the base plate on my plunge router, model dw621. I got a new base plate c/w the columns already in place. I was able to remove the rubber sleeve and spring in the larger column but it wont come out. How do I remove the base plate and install the new one?
My router runs then stops each time I pull the trigger. I can see that the magnet is missing. Will a new magnet fix the problem or will I need a new speed control module? I got this on ebay cheap, so I have a small budget to work with.
I have a Dewalt 621 Type 1 router. The adjustment knob that raises and lowers the router to the set height turns without the router moving. It seems to be stripped or jammed. Any helpful hints?
I have a DW621 which suddenly stopped working! I have replaced the brushes but this hasnt made any difference. The motor doesnt smell as if it's burnt out. I had it running once by running a feed directly to the connectors next the brushes. But it doenst seem to run anymore. I am running out of parts to test, could the motor be at fault. How do I check the motor? I know a feed is getting to the brushes.
It sounds like you have a break in the field.The field can be tested with a ohm meter .
Reply: DeWalt DW621
amazontoolrepair
Like Tinkerdave said, its portably a break in the field, but it could also be the armature.
Use a continuity tester, with the motor assembled, check for continuity from the white wire going in, to the black wire going in. You should have continuity between the two, if you don't, proceed with the following tests. If you do, then the motor is not the problem.
Using a continuity tester, put the probe on the contact of one side on the armature, then put the other probe on contact of the opposite side on the armature. If you have continuity across the armature then the armature is most likely good. If you don't, then the armature will need to be replaced.
Now check continuity through the field. You will see where the electrical input goes in the front of the field, pick a side (right or left), put the probe on the input, around the back of the field (on the same side) would be the output. You should have continuity from the front to the back of the field on one side. Then do the same thing to the opposite side. If you do not have continuity on one or both sides then the field would be to be replaced.
I didnt have instructions but this is what I figured out. I assume you can locate all the obvious screws, there is one more under cord/switch cover. Leave the two long plastic screws in top unless you need the motor brushes and or speed sensor module. no need to remove the handles. You need to remove the three metal screws holding the shaft pinning mechanism. Underneath that cover, look closely, the large washer is actually a threaded spacer. Put a screwdriver through shaft and remove that washer. There are two holes in it for a speccial tool, I used a channel lock. Pry back very top edge of rubber boot and remove the clip holding the spring mechanism (look at a parts diagram for a better understanding what to look for) The only way for me to get the armature loose and separate the casings at this point was moderate but persistent rubber mallet persuasion on the end of the shaft where the collet is. It took several blows but it fianally released and the router was apart. My cooling fan had shifted and was making a scraping sound. I gently budged it into place (lowered it 2mm) and reassembled and I am happy.
Good luck.
IXFE
I am trying to remove the case of a Dewalt 621 router to investigate a stalling problem but after removing the casing screws I am unable to remove the case because it seems to be stuck at the base of the plunger tube where the spring is. I get the impression that if I can release the spring the case will come free. I can remove the clip at the top of the spring but cannot seem to get access to remove the clip at the base of the spring.
My new DW621 exceeded all my expectations. Moving up from a 1 1/2 HP Ryobi, the Dewalt is a precision machine that is compact, light and powerful. It is a joy to use and is my favorite router now. Thanks.
Call us toll free 6:30 to 5, Mon-Fri, mst 866-802-6383
Power Tool Parts 
