Introduction

The motor inside the DW660 uses two carbon brushes which transfer electricity to the rotor by sliding over the copper commutator. The brushes wear out over time with regular use, so they will eventually need to be replaced.

Parts

No parts required.

Remove the four 19mm T20 Torx screws at the rear of the device. Remove the four 19mm T20 Torx screws at the rear of the device.
  • Remove the four 19mm T20 Torx screws at the rear of the device.

Remove the other part of the back casing. Unplug the black and white power wires from the motor. Unplug the black and white power wires from the motor.
  • Remove the other part of the back casing.

  • Unplug the black and white power wires from the motor.

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Pinch the blue brush wire between two fingers. Pull on the wire, removing them from the motor.
  • Pinch the blue brush wire between two fingers.

  • Pull on the wire, removing them from the motor.

Using the metal spudger,  lift up the coil spring that holds the carbon brushes in place. While the spring is lifted up, remove the carbon brush by simply sliding it out of the slot.
  • Using the metal spudger, lift up the coil spring that holds the carbon brushes in place.

  • While the spring is lifted up, remove the carbon brush by simply sliding it out of the slot.

Repeat steps 3 and 4 to remove the other carbon brush. When installing the new carbon brushes, make sure each brushes' lead wire is plugged into opposite ends of the motor.
  • Repeat steps 3 and 4 to remove the other carbon brush.

  • When installing the new carbon brushes, make sure each brushes' lead wire is plugged into opposite ends of the motor.

  • Refer to the photos for visual assistance.

Conclusion

To reassemble your device, follow these instructions in reverse order.

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Joseph Pacitto

Member since: 03/23/2016

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