Dremel 4000 Electrical Assembly Replacement Repair Guide

Difficulty

Moderate

Steps

Time Required

                          15 minutes

Sections

Back Case
6 steps
Power Cord
4 steps
Bearing Assembly
2 steps
Electrical Assembly
2 steps

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Introduction

What you need

Step 1

              Back Case

Start by removing the housing cap by unscrewing it.
Next, unscrew the now exposed collet nut while holding down the shaft lock button.
To remove the collet nut, you may need to use the small open-end wrench provided with the Dremel.

Start by removing the housing cap by unscrewing it.

Next, unscrew the now exposed collet nut while holding down the shaft lock button.

To remove the collet nut, you may need to use the small open-end wrench provided with the Dremel.

1024

Step 2

Using your hands, carefully remove hanger from casing.

Using your hands, carefully remove hanger from casing.

Step 3

Remove the brush caps (one on each side) by using a flathead screwdriver bit.
The brush caps are spring loaded.

Remove the brush caps (one on each side) by using a flathead screwdriver bit.

The brush caps are spring loaded.

Step 4

Using the Torx 15 screwdriver tip, remove the 5 screws (12.5 mm) that hold the casing together.

Using the Torx 15 screwdriver tip, remove the 5 screws (12.5 mm) that hold the casing together.

Step 5

Use a plastic opening tool to gently wedge apart the hard plastic threads.

Use a plastic opening tool to gently wedge apart the hard plastic threads.

Step 6

Use your hands to carefully remove the back casing so that none of the components fall out.

Use your hands to carefully remove the back casing so that none of the components fall out.

Step 7

              Power Cord

To clear access to the electrical assembly, remove the variable speed dial cap and blue power lever, and set them aside.

To clear access to the electrical assembly, remove the variable speed dial cap and blue power lever, and set them aside.

Step 8

Using your fingers, carefully pull the circuit board from the casing. This will make it easier to remove the power cord.

Using your fingers, carefully pull the circuit board from the casing. This will make it easier to remove the power cord.

Step 9

Each wire is fed through a small opening on the circuit board and held with a flat head screw.
Loosen the screw just enough to remove the wire by gently pulling it with your hand.

Each wire is fed through a small opening on the circuit board and held with a flat head screw.

Loosen the screw just enough to remove the wire by gently pulling it with your hand.

Step 10

Carefully remove both wires from circuit board with your hands.
Take careful note of which side has the black wire and which has the white wire.

Carefully remove both wires from circuit board with your hands.

Take careful note of which side has the black wire and which has the white wire.

Step 11

              Bearing Assembly

Carefully pull up on the shaft to lift out of the casing.

Carefully pull up on the shaft to lift out of the casing.

Step 12

Firmly hold the field assembly in one hand and the bearing assembly in the other.
Carefully slide the bearing assemble out of the field assembly.

Firmly hold the field assembly in one hand and the bearing assembly in the other.

Carefully slide the bearing assemble out of the field assembly.

Step 13

              Electrical Assembly

Firmly hold the field assembly in one hand, and carefully pull free the red and black wires that connects the electrical assembly to the field assembly.
Take note which slot gets the red wire and which gets the black wire for proper reassembly.

Firmly hold the field assembly in one hand, and carefully pull free the red and black wires that connects the electrical assembly to the field assembly.

Take note which slot gets the red wire and which gets the black wire for proper reassembly.

Step 14

This is your completely removed electrical assembly.

This is your completely removed electrical assembly.

To reassemble your device, follow these instructions in reverse order.

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                                                                                      22 other people completed this guide.

Author

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                    John Cobb

Member since: 01/20/2016

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Team

                       USF Tampa, Team 15-4, Remmell Spring 2016                        

                                                  Member of USF Tampa, Team 15-4, Remmell Spring 2016 



                    USFT-REMMELL-S16S15G4                     


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                                            11 Guides authored

Tom Hartsell - Mar 9, 2017

One of the brush holders has a component…small capacitor… ten cent part. If somebody can identify the value of the component, I could fix mine now that I’ve replaced the control board and still won’t start. I shorted across the component and suddenly came to life.

Jozef Kutej - Aug 27, 2018

DF110S 110c Thermal Fuse 16A 250V

“Thermal fuse DF is an one shot device, after operating function have to be replaced.”

Mercedes Joy - Jun 9, 2017

Anyone with info about the third wire (on mine is blue ending with a small copper clip) serves? This is connected off of the switch, labeled W5 on the circuit board. [Edit. It is a ground] I suspect it is a feed back wire for speed sensor? But where does it attach? Some wear on the abovementioned capacitor crossing one of the brushes. Anny ideas?

louisloria - Sep 22, 2017

You see the copper bushing slot at the top of the picture (next to the guy’s index finger) from step 9? Directly underneath it where the slot sits, there’s a tiny notch in the gray frame. Once you pull off the bushing slot from the frame (if you haven’t already), slide the small copper clip (from your 3rd blue wire) onto that notch. Then you push the bushing slot back onto the frame where it was. Essentially, the copper clip is “grounded” to that bushing slot.

D Lee - Dec 28, 2022

An even better photo in step 11 showing the copper clip on the blue wire located beneath the copper brush holder

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