Bosch Colt router losing power at all speeds.

[Paul Kincaid]

I have a router that I use for teaching that recently started having some problems. It's at a public shop that I am not always at, so I don't always know how the tools are being used and they get a lot of "use". I have two identical routers at my own shop that are older and used more often with no problems. The damaged router starts and reaches speed as usual. The brushes have over 1/4" left before hitting the springs. The symptoms are at all speed settings and all sizes of bits. It loses power when applied to even a modest load, almost to the point of stopping. The bearings seem to be in good order. Any ideas?

[Greg Robinson]

Partially shorted windings would cause these symptoms, if the router had been pushed too hard, it could have shorted some windings without killing it completely.
You could try measuring the DC resistance of your working routers and compare to the faulty one, it may read a bit lower.

[Steve Senseney]

Another thought, check the brushes. If they are worn out, they may not be making good contact, and they can be replaced relatively easily.

[David King]

You can try resurfacing the brushes and commutator yourself to see that helps. Bearings could also be affecting speeds. I'd consider these routers "disposable" since the repairs often add up to more than the new replacement. I've had several variable speed controls/triggers go south on me and the part price was always a surprise. At least bearings and brushes can usually be sourced independently. Bosch prides itself on it's 700 Rapid Repair Service Centers. One of them should be close by.

[Paul Kincaid]

I may just buy a new router and keep the one from class for parts. The parts aren't too expensive, but they add up quick and I'll eventually need parts for my own.

[Chuck Tweedy]

That sounds like a good plan to me. If it is as Greg suspects, then it is only good for parts.