Reel Mover Motor Brush Maintenance & Replacement Guide

Proper motor brush maintenance is essential to keep your PowerHandler® reel mover delivering reliable performance, maximum efficiency and a long motor life. Regular inspection and timely replacement of motor brushes helps prevent unexpected failures, reduces maintenance costs and keeps your equipment operating at peak performance.

This guide walks through MBM’s full brush inspection and replacement procedure, step by step. You can also download the complete printable PDF booklet at the end of this article.

Important safety notice: Always disconnect and remove the battery before carrying out any inspection, maintenance or repair work on your PowerHandler.

Step 1 – Isolate the Power Supply

Figure 1 – Removing the battery

Before performing any maintenance or repair work:

• Switch off the PowerHandler.
• Disconnect and remove the battery.
• Verify that all power sources have been isolated.

Safety first: never attempt motor maintenance while the machine is connected to a power source.

Step 2 – Inspect the Brush Housing

Figure 2 – Checking the brush housing for external damage

Conduct a visual inspection of the brush housing for signs of:

• Impact damage
• Cracking
• Distortion
• Physical wear

This inspection is typically unnecessary if a Cable Guard is fitted, as it provides full protection for the brush assembly.

Why this matters

Evidence of impact damage may indicate that a brush has contacted the motor rotor while rotating, potentially causing permanent rotor damage.
If no damage is visible:

• Use a 5mm Allen key.
• Remove the six motor guard retaining bolts.
• Carefully remove the bolts and store safely for reassembly.

Step 3 – Remove the Motor Guard

Figure 3 – Sliding the motor guard clear of the motor and main frame

Carefully slide the motor guard away from the motor and main frame. During removal:

• Take care not to trap or damage the power cables.
• Inspect cable insulation for wear or damage.

If cable insulation is damaged

• Replace the cable assembly (contact your MBM representative), or
• Thoroughly wrap the affected area using suitable electrical insulation tape.

Damaged insulation may cause electrical short circuits when the unit is reassembled.

Step 4 – Remove the Brush Cover

Figure 4 – Unscrewing the brush cover

Using an appropriately sized flat-blade screwdriver:

• Unscrew the brush cover.
• Carefully remove the cover.
• Avoid damaging any plastic components during removal.

Proper care during this stage helps maintain the integrity of the brush housing and cover assembly.

Step 5 – Remove the Motor Brush

Figure 5 – Removing the brush assembly

Remove the brush assembly by:

• Grasping the brush firmly.
• Pulling straight upward from the housing.

Avoid twisting or forcing the brush, as this may damage the housing or internal components.

Step 6 – Measure Brush Wear

Figure 6 – Measuring brush length

Carefully measure the brush length from the step on the brush to the end of the carbon brush.

Recommended practice

If any one brush measures less than 3mm, replace all four brushes as a complete set. This ensures:

• Balanced motor performance
• Consistent transfer
• Reduced component wear
• Maximum motor efficiency

Step 7 – Confirm Components for Reassembly

Figure 7 – Brush assembly components: housing, spring, carbon brush, felt washer and plastic cover

After inspection, ensure the following components are present and in good condition:

• Plastic cover
• Felt insulator washer
• Brush assembly: spring, carbon brush, braided cable
• Brush housing

Inspect each part for wear or damage before reassembly.

Essential cleaning procedure

Before installing new brushes, thoroughly clean the motor. Remove all carbon brush deposits using compressed air and/or an approved electric motor cleaner. It is critical that all carbon dust and debris are removed from the motor before reassembly.

Benefits of proper cleaning:

• Improved brush seating
• Enhanced electrical contact
• Reduced wear
• Increased motor life
• More reliable machine operation

Reassembly

Reassemble the motor and machine by reversing the procedure described above. During reassembly:

• Check that no wiring is trapped or damaged.
• Confirm cable insulation remains intact.
• Tighten all fasteners securely.
• Refit the battery only after all work has been completed.

MBM Preventive Maintenance Recommendation

To maximise machine availability and extend motor life, MBM recommends:

• Regular brush inspections as part of scheduled servicing.
• Immediate replacement of worn brushes below 3mm.
• Keeping motors clean and free of carbon deposits.
• Prompt repair of damaged wiring and housings.
• Using genuine replacement components whenever possible.

Need the full printable version, or replacement parts?

Download the complete PDF instruction booklet for printing or workshop use, or get in touch with the MBM team for genuine replacement brushes and technical support.
Download: Power Handling Reel Movers – Motor Brush Maintenance & Replacement Instructions (PDF)
Email: sales@mansfieldboard.co.uk
Phone: +44 (0)1604 713656
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