About motor brushes
Two graphite brushes convey electric power to the motor commuta-
tor. Brushes are a consumable item, and have a lifetime of about 650
operating hours. Operating without the air intake filter lets airborne dirt
and moisture enter the motor; this can reduce brush life substantially.
When brushes are worn the motor does not operate properly.
If you must replace motor brushes, we recommend installing a
M
OTOR
S
AVER
brush on one side. The M
OTOR
S
AVER
brush contains an
insulating pin to shut down the motor when the brush is worn,
minimizing the chance that the motor will drag and scratch the
commutator. Replacement brush part numbers are:
030: Brush kit (two standard brushes), 120 VAC.
032: Brush kit (two standard brushes), 240 VAC
033: Brush kit (one standard, one M
OTOR
S
AVER
), 120 VAC.
034: Brush kit (one standard, one M
OTOR
S
AVER
), 240 VAC
How to replace motor brushes
Unplug power cord to prevent shock. Remove front housing (see
“Simple Workstation”) to access the motor. Identify the two motor brush
housings on opposite sides at the top of the motor.
Insert a small flat blade screwdriver between the motor wire/termi-
nal and the plastic brush housing. Gently pry terminal out, pushing it
towards the commutator until it is loosened. Take care not to break the
terminal contact or the wire. If the plastic brush housing is very tight, heat
slightly with a hair drier or heat gun to soften before sliding the wire/ter-
minal out. Repeat for the second brush.
Remove two Phillips head screws and retaining bracket holding one
motor brush. Lift brush off motor frame and discard.
Hold replacement brush in position (tab pointed down). Press the
motor wire terminal (flat brass piece) partially into the brush assembly,
between the brass shell and the plastic housing.
Slide the brush assembly towards the commutator until the tab seats
in the notch on the motor frame. Replace retaining bracket and two
screws. Then slide or pry the wire terminator securely back into the brush
housing with the screwdriver.
Repeat for other brush.
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