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Got a dw004 24v sds. just changed brushes, old ones pretty good. unit drops in speed by id say 1/3. every now and again kicks back into life. could this be the switch

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More than likely, i had a similar problem on a d/w 18v impact driver a friend gave me 'cause he thought it was dead, i replaced the switch and it has been working ever since

Posted on Nov 14, 2009

Testimonial: "cheers dude. thought it prob was as runs fine. just done my impact too. once again. many thanks"


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Hitachi 24v sds hammer drill issues with speed when pulling back trigger switch sometimes works other times nothing, already changed dc speed control trigger any ideas to what the problem is? Thanks

faltering on a slide contact on electric field or switch, but in most cases dirth (dust) in carbonbrushes can be hanging somewhat in one or both brushholders.
Or a problem in the trigger switch itself dust and dirth have almost the highest priority in case of faltering by clamping carbon brushes.

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Does anyone have advice on what to check next if you've changed the brushes on a BHR202 and it still doesn't work?

Is there a Deep discharge protection connector on your powertool ????

The thirth small contact in the battery connector or only 2 contacts ?

If not then its an advise it must be modificated then you have only to break off a notch on the new modificated battery holder connector so it can be placed in the older not marketing technical modificated housing, and you have to change the switch and the battery connector , the differences are 091A. 643844-1 old batteryconnector (2 contacts) change into 091B. 644808-8
New modified batteryconnector (3 contacts with deep discharge protection it has a limit until a level)
088A. 650578-9 Switch old model (2 contacts) replace for a
088B. 638882-6 New modified switch (3 contacts )

What you need is even expensive by this model if you have a modified type with the 3 contacts to know what can be wrong else is remove the brushes charge you battery and measure it first if its full and take a multimeter measure tool between both brushholder measure and pull the trigger that must between give 16and 20 volt DC if the battery was good charged . next measure is ohms resist measure both brushes in the brushholders and measure for a few ohms from brushcontact to brushcontact throught the armature inside the machine.
if not a resistance to get measure through the armature without brushes if some object or parts was comming trough the ventilation of the machine between armature and brusholder then the brush beet not the collector anymore different things to look at .
26116694-xaq5q3decq2piqybkt2ddcrv-2-0.jpg Look also how the kind of wiring technik of the armature is different left is a old kind of armature that will last for 5 years or more its having thicker wiring and an other winding pattern instead of the modern kind of armatures from the last years from 2009 and later Johnson armatures by PANASONIC MILWAUKEE, MAKITA , this new armature has a lot of more power but its faster defect because of the to tight tolerance of heat dissipation and ventilation but thats most in time of inbetween 2 or 3 years worn by the great strength and light machine makes this rapidly abuse when it is going to slowly get gives a shrill sound then i know there is also not much power on , batteries are fast empty and no power left ( AND THE PROBLEM IS PEOPLE THINK THE BATTERIES ARE GETTING OLD no thats not the problem but the armature is it and as before its eating carbon brushes in between 1 month again so fast if its worked in daily use. ALWAYS REPLACE BRUSHES AND ARMATURE (thermical shortings not to see but to hear and measure) at the same time it isnt not so expensive as that you choose new batteries and the batteries work great on a other tool . if the machine has eating the brushes with the old armature left on picture nothing was happens and it last again in good condition but the power difference is great between the old and the new armatures of the brand Milwaukee 18V to compare this old was Milwaukee 18volt and right the same kind of new sensitive armature like Panasonic or Makita have used in their tools.

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How do I replace brushes on this drill?

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My drill start to smoke after 20-30secs of runing

Replace the brushes and clean the unit
My answers are short and sweet. Common sense mostly. If you are trying to get something for nothing...Don't waste my time! Remember if something sounds to good to be true that it usually is. I've spent many years of my life trying to cheat the system and was pretty good at it. This all changed when I discovered that people were doing the same thing to me. What comes around, goes around. Karma! Now I assist people in making win-win deals...that are legit!

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This should get your unit back in operation. If you find this solution helpful, I would appreciate a Thumbs Up from you. Thank you. Paul

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