Ryobi D620H Motor Brush Replacement

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Before You Start

For your safety, ensure the Ryobi D620H Hammer Drill is not connected to any power source before you perform any repairs.

It is very important to ensure that the electrical connections are correctly replaced in their designated area for the drill to function properly.

Replacing the motor brushes is a very detail-oriented process. It is crucial to ensure you are paying attention to the positions of each wire. If you mix up even one of the connections, the drill will not function after reassembly! If a cellphone with a camera is accessible to you, it will help to take close-up pictures of the drill before disassembly or you can use a marker to mark the wires to their corresponding connections.

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crwdns2931653:01crwdne2931653:0 Right Side Case Removal

Ryobi D620H Motor Brush Replacement, Right Side Case Removal: crwdns2935265:01crwdnd2935265:01crwdnd2935265:01crwdne2935265:0

Turn the drill so that the screws (circled in red) face upwards.
Use the T20 screwdriver to remove all nine screws.

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Ryobi D620H Motor Brush Replacement: crwdns2935265:02crwdnd2935265:01crwdnd2935265:02crwdne2935265:0

Ryobi D620H Motor Brush Replacement: crwdns2935265:02crwdnd2935265:02crwdnd2935265:02crwdne2935265:0

Insert a flat object between the right and left sides of the drill to lift the right side of the case.
Remove the right side case to expose the inside of the drill.

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crwdns2931653:03crwdne2931653:0 Motor Brush

Ryobi D620H Motor Brush Replacement, Motor Brush: crwdns2935265:03crwdnd2935265:01crwdnd2935265:01crwdne2935265:0

The motor brushes are located on the rotating armature of the motor.
Look for the large dark gray metal housing in the center of the body of the drill, this is the motor.
The armature of the motor by finding the chuck and the transfer gears, and then look at the other end of the motor. There is a small copper barrel (armature) that is likely colored dark gray from the carbon brushes rubbing against the armature.
On the top and bottom of the armature (small copper barrel), there are brass spring-loaded brackets holding blocks of carbon against the armature; these blocks are the motor brushes.

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Ryobi D620H Motor Brush Replacement: crwdns2935265:04crwdnd2935265:01crwdnd2935265:02crwdne2935265:0

Ryobi D620H Motor Brush Replacement: crwdns2935265:04crwdnd2935265:02crwdnd2935265:02crwdne2935265:0

Unscrew the brass spring-loaded bracket from the case using a PH1 screwdriver and remove them from the case and armature.
The motor brush will likely partialy self-eject from the brass brackets.
It is highly recommended to replace one motor brush at a time to not mix up the wiring.
Unscrewing the brush brackets is the same for both top and bottom.

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Ryobi D620H Motor Brush Replacement: crwdns2935265:05crwdnd2935265:01crwdnd2935265:01crwdne2935265:0

Pull the two connections (circled in red) gently from their terminals.
The longer white wire connects to the left side terminal and the shorter white wire connected to the brush connects to the right side terminal
Remove the composite shim under the bracket.

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Ryobi D620H Motor Brush Replacement: crwdns2935265:06crwdnd2935265:01crwdnd2935265:01crwdne2935265:0

Remove screws and disconnect the two terminals circled in red on the bottom brush bracket.
Remove the longer black wire that connects to the left side terminal
Remove the shorter white wire connected to the brush that connects to the right side terminal
Remove composite shim under the bracket.

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Ryobi D620H Motor Brush Replacement: crwdns2935265:07crwdnd2935265:01crwdnd2935265:02crwdne2935265:0

Ryobi D620H Motor Brush Replacement: crwdns2935265:07crwdnd2935265:02crwdnd2935265:02crwdne2935265:0

This process is identical for the top and bottom brushes as they are mirrored.
Remove the right-side wire from terminal. (The wire that connects to the brush).
Pull the brush out of the brackets gently. It shouldn't require much force.

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Ryobi D620H Motor Brush Replacement: crwdns2935265:08crwdnd2935265:01crwdnd2935265:02crwdne2935265:0

Ryobi D620H Motor Brush Replacement: crwdns2935265:08crwdnd2935265:02crwdnd2935265:02crwdne2935265:0

Place the new coil spring on the new bracket.
Slide the motor brush wire into the bracket and connect it to the right-side terminal.
Reconnect the longer white wire on the top brackets left side terminal by firmly and steadily pushing down.
Reconnect the longer black wire on the bottom bracket left side terminal by firmly and steadily pushing down.
Replace the composite shim under the brackets.
Screw both brackets down.