How to Replace the Motor Brushes on a DeWALT Shear

Your shear's motor uses two carbon brushes to conduct electricity to the armature. The brushes do this through the armature's commutator. The carbon brush will wear down over time (from rubbing against the rotating commutator) and will need to be replaced. Worn brushes can cause excessive sparks around the commutator. The sparks can also be caused by a damaged armature, so you'll want to carefully inspect both components if sparks are present.

Let's get started.  

REMOVING THE MOTOR BRUSHES   1. Remove the handle cover.

a. Remove the (3) screws securing the handle cover to the motor housing.

b. Remove the handle cover from the unit.

  2. Remove the motor brush.

a. Use a small pick to lift (and hold) the brush spring away from the motor brush.

b. Remove the motor brush from the brush holder.

INSTALLING THE NEW MOTOR BRUSHES

  3. Install the motor brush.

a. Install the new motor brush into the brush holder.

b. Allow the brush spring to pivot back into the slot on the top of the motor brush.

  4. Repeat.

a. Repeat these steps to replace the second motor brush (on the opposite side of the motor).

REASSEMBLING THE UNIT

  5. Reinstall the handle cover.

a. Install the handle cover.

b. Secure the handle cover with the (3) screws.