Dewalt D26200 Router_ Replacing the Brushes.

In this Instructable I will show you how to replace the brushes in a Dewalt D26200 Compact Router.

This is quite a popular Router within Hobby CNC circles, I have an Ooznest Ox CNC and the D26200 was an option that came with the CNC kit when new.

I've replaced the brushes on a couple of occasions now and feel confident in explaining the process.

If the brushes expire, then the router just stops spinning and this could dig into the job ruining it, so its best to check them on a regular basis depending on how much usage the Router gets of course.

Its a fairly simple process now that I have found out how to replace them.

The process:

Pair of long nose pliers

Small flat head screw driver

Torx screw driver or bit

2 New Brushes

There are a few precautions to heed to before carrying out any work.

The most important thing you need to do before starting anything is turn the power off to the router and unplug it at the switch.

In the UK the voltage is 230v and it can kill, in the states 120v I believe.

The Brushes can be replaced with the router in situ, there is a need to release the router clamp at some point to spin the router to gain access to the 2nd set of brushes, screw the z down until the router is sat on the spoil board this stops it from dropping too far down through the clamp, mark the position of the router in the clamp just in case it slips.

There are 4no Torx head screws which secure the top of the router to the main body of the router, remove these screw and then remove the top of the router, slide the top down the cable so it is out of the way.

The brushes can be seen clearly with the top removed, there are 2 and are opposite each other, the brushes are spring loaded and brush up against the stator.

There is an unshielded wire coming from the rear of each brush, take the long nosed pliers and remove the spade connector.

To release the tension on the spring, you can use a small screwdriver or something pointed like a bradawl, just tease the coil of the spring out and place it to one side of the brush holder as in the photos, the spring is attached to the holder, it wont fly out.

With the tension released and the spring out of the way, we can use the cable to extract the brush from its holder, compare the brush to the new replacement, if there is less than a third left then I would replace both brushes.

Installing the new brushes:

Prior to installing the replacement brushes, I get my Air pressure gun, slip on a dust mask and safety glasses and give the internals of the router a good blow out with the Air gun, its amazing how much dust comes out of it:)

I have on occasion thought that the spindle locking pin was on its way out, only to find its full of dust, and a good blow out does the trick

Installing the brushes is just like removing them but in reverse, slide the new brush into the holder, and with a screw driver gently ease back the spring and it will snap into position up against the brush applying the necessary tension for it to engage the stator, fit the cable spade connector back in position, or fit the cable first it doesn't matter, then all there is left to do is to refit the top of the router and tighten the screws, adjust the router back to its working position and tighten the screws on the clamp, job done!

I can imagine getting this sort of work done would cost at least 1 Hours Labour and to buy these yourself they are around £14 or $19

Thanks for looking.