How to Replace the Carbon Brushes on a DeWALT Angle Grinder (Model D28402)
If broken parts and faulty starts are grinding on your nerves, it's time to face the fix. Whether you are a grinding pro or seasonal grinder, eReplacementParts.com provides the parts, procedures and facts you need to fearlessly fix what fails you.
Motor brushes allow electricity to flow to the motor's spinning armature. The brushes, which are made of carbon, will begin to wear down over time. When this happens, the motor no longer receives the electricity it needs to function smoothly. Symptoms of worn brushes include erratic or intermittent operation, decreased power, or a complete inability to activate the grinder.
This article provides step-by-step instructions for replacing the carbon brushes on a DeWALT D28402 grinder. Let’s get started.
REMOVING THE BRUSHES [top]
1. Remove the top half of the handle assembly.
Remove the (5) retaining screws.
Remove the top half of the handle assembly.
2. Separate the handle from the field case.
Remove the paddle assembly.
Remove the lock-on button assembly.
Separate the handle from the field case.
3. Remove the brushes.
Use long-nosed pliers to remove the brush wire from the terminal.
Use long-nosed pliers to lift the brush spring away from the brush arm.
Lift (rotate) the brush arm assembly to access the brush.
Remove the brush from the arm assembly.
Repeat this process to remove the second motor brush (on the opposite side of the grinder).
INSTALLING THE NEW BRUSHES [top]
4. Install the brush.
Insert the brush lead (wire) through the opening in the brush arm.
Seat the new brush into the brush arm assembly.
Lower (rotate) the brush arm assembly into position above the armature.
Reinstall the brush wire.
Use needle-nosed pliers to re-engage the brush spring.
Repeat this process to install the second motor brush (on the opposite side of the grinder).
REASSEMBLING THE UNIT [top]
5. Reconnect the handle assembly to the field case.
Partially connect the lower half of the handle assembly to the field case.
Tuck the wires into the designated slots and channels on the assembly.
Connect the lower half of the handle to the field case (manipulate the two components until they “snap” into place).
6. Reinstall the lock-on button.
One side of the lock-on button contains a small tab. This tab should be installed facing the armature.
Install the lock-on button into the handle.
7. Reinstall the paddle assembly.
Install the paddle assembly into the handle; ensure that the “tail” is positioned above the switch button, and the “fulcrum” is seated within the recess in the handle.
8. Reinstall the top half of the handle assembly.
Partially install the top half of the handle assembly.
Align the posts (on the fulcrum and the lock-on button) with the recesses in the top of the handle.
Before securing the handle with the screws, test the paddle and the lock-on button for proper functionality.
Secure the handle with the screws.
You can't place a value on a job well done, unless you did it yourself. (Which you did.) Now you can place that value back into your own pocket. (Or into your business.) Not only did you refine your grinder at a fraction of the cost of replacement; you have expanded your skills far beyond the daily grind.
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