Reply by JBrow

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Posted on Dewalt dw 621 router stiff

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1368 posts in 1431 days

#1 posted 08-09-2016 02:19 AM


When my DW621 plunge router started giving me troubles I replaced it with a new DW621. Upon removing the new DW621 from the box I found the same issue; the plunge mechanism would stick when the trying to plunge the router from its home position making it difficult to use. After a little work, the plunge mechanism now works fairly smoothly, but still has just a little (very slight) stick once in a while.

I first used acetone to thoroughly clean the plunge columns. Once cleaned, the router was turned upside down and low viscosity sewing machine oil was applied all around the plunge rods. Then base of the still upside down router was worked up and down, trying to spread out the oil and work it into the plunge column housings. It took quite a few times but it eventually the stick was mostly overcome. After the plunging mechanism loosened up, I wiped excess oil from the plunge column with a paper towel. The router can now be safely used since plunging during operation is easily done. However, after it has set unused and I pull it out, I find that there is a slight resistance to the first plunge, but thereafter it operates smoothly. I figure the more it is used, the more smoothly it will operate.

Over time I expect that the plunge mechanism will stiffen up due to dirt and dust; it did on the old DW621. I found that cleaning and wiping the plunge columns and re-applying oil, working it into the plunge column housings, freed it up again.

If you have had the router apart my other thought is that the plunge depth lock mechanism may not be installed quite right.

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