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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
of carbon remaining, or if the spring or wire
in.
is damaged or burned.
c. Use a slotted screwdriver to remove the black plastic
cap 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 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 the 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.
WARNING: If the supply cord is damaged, it must be replaced by a specially prepared cord
available through the service organization.

Lubrication

All of the bearings in this tool are lubricated with a sufficient amount of high-grade lubricant for the
life of the tool under normal operating conditions. Therefore, no further lubrication is required.
WARNING: Turn the switch to the "OFF" position and remove the battery pack from the tool
before performing troubleshooting procedures.
35
32
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