Brush Motor Replacement Kit

This new version of the brush motor and mount retains all the advantages of the original and includes some improvements to reliability, durability, and debris collection. It has more POWER so the new DuctMasters have a 2 position switch for HI and LOW. Installing a new motor in a DuctMaster without the Hi/Lo switch could run the FIRM brush fast enough to cause damage to older ducts. If in doubt about the ducts condition, use the SOFT 12” brush with the smaller, .021” bristles. Contact Air Care for questions about using the newer motor on existing DuctMasters or TruckMasters. 702-454-5515.

The hoses, motor and electrical connections for the new version will fit previous DuctMaster models.

KEEP THE NEW MOTOR FULLY ASSEMBLED!

First remove the OLD motor and mount from your hose:

1. Remove the screws holding the motor mount collar on the end of the hose and save the screws and nuts to mount the new motor and mount. One screw also secures the internal stiffener to the interior of the hose. (Some stiffeners are steel, and some are fiberglass)

2. Cut the 3 wires for the motor leaving enough cord to crimp (or solder) the wires to the new motor wires. All 3 wires will need to be the same length for this new motor connection.

3. You will no longer need any of the parts in the original motor assembly unless you are returning it to Air-Care with an RMA for warranty evaluation.

Installing the NEW Motor Assembly.

1. Be sure you have all the parts for the installation.

    a. Your original screws, 10-32 x 5/8” long machine screws,

    b. 10-32 hex nuts with built in lock washers.

    c. Metal or fiberglass stiffener (if it was on the original hose)

2. Remove the outer insulation from the black power cord in the hose to expose the 3 insulated motor wires about 2 inches long.

3. Strip the insulation from all 3 wires about ½” back from the ends.

4. Slide the larger black shrink tubing over the cable. It will slide over the new connections after the wires are connected.

5. Slide the 3 pieces of smaller shrink tubing over each of the motor wires. The connections can be made by crimping the new connectors or soldering them. If you are planning to solder the connections, be sure the blue shrink tubing is far enough away from the heated ends to prevent it from shrinking prematurely from the heat of soldering.

6. The wires may be different colors from the motor than the ones from the hose cable. The order is not important, the brush will operate with any combination of wires, but it may turn in the opposite direction in some cases but will still change directions as before.

7. Each of the 3 wires from the hose can now be inserted into the crimp connectors on the new motor. Try to twist the wires tight enough so that all the strands go into the silver connector, then crimp it with a crimping tool. Alternately, the wires can be soldered, if so, be sure they are heated to a point where the solder flows into all the strands and into the silver connector. The motor is a low voltage, HIGH AMP device and a poor connection will result in faulty performance.

8. Slide the blue shrink tubing over the metal connector; Heat the tubing to shrink it in place. A hair dryer, heat gun or even a cigarette lighter can be used. Be careful to not burn yourself, the plastic hose or heat the other shrink tubing at this time.

9. Connect the other 2 wires following the same procedure.

10. When all 3 wires are connected and insulated, slide the larger black shrink tubing over them and as far towards the motor as possible. Heat this shrink tubing to shrink it on to the wires.

11. Next, slip the nylon loop strap over the wires. This will guide the wires. The loop strap will be held in place with one of the 10-32 x 5/8” screws used to hold the black nozzle on the hose.

12. Insert the screws into the mounting holes in the nozzle and thread the screws into the original holes in the hose if possible. If this is difficult, you may need to drill new holes in the hose using the 2 holes in the black nozzle as a guide. Use a 3/16” diameter drill.

13. When the screws are in place, place the loop strap hole over one of the screws and install one of the nuts then tighten the screw with a screwdriver. It may be necessary to use a screwdriver to thread the screws through the loop strap.

14. If your hose has a stiffener, install its loop over the other screw, install the nut and tighten it. If there is no stiffener, just install the nut and tighten the screws.

15. Your repair and upgrade are now complete and ready to test. If you have any questions, please call Air-Care Tech Support, 800-322-9919.