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CARE AND MAINTENANCE
35. Replacing Carbon Brushes
a. Unplug the router motor before inspecting or
replacing brushes.
b. Replace both carbon brushes when either has
less than 1/4 in. of carbon remaining, or if the
spring or wire is damaged or burned.
c. Use a slotted screwdriver (not included) to
remove the black plastic cap (J) on each side
of the router motor. Carefully remove the
spring-loaded brush assemblies. Keep brushes
clean and sliding freely in their guide channels.
d. Insert new brush assemblies into the guide
channels, with the carbon part going in first,
and be sure to fit the two metal “ears” into their
slots in the channel.
NOTICE:
To reinstall the same brushes, make sure that the brushes go back in the same way
they came out. This will avoid a break-in period. Insert new brush assemblies into the guide
channels with the carbon part going in first, and be sure to fit the two metal “ears” into their
slots in the channel.
e. Remember to replace both end caps after inspecting or servicing the brushes. Tighten the
caps snugly, but do not overtighten. The router should be allowed to “RUN IN” (run at no
load without a cutter bit) for 5 minutes before use to seat new brushes properly.
WARNING
• When servicing, use only identical replacement parts. The use of any other parts may create
a hazard or cause damage to the product.
• If the supply cord is damaged, it must be replaced by a specially prepared cord available
through the service organization.
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J
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