DeWalt Early Motor Insulation Breakdown / Overheating

Vacuum produces a strong electrical or ozone-like smell but no visible smoke

This repair may involve working with high voltage components or water connections. Always unplug the appliance before removing any panels.

If you are not confident in your ability to perform this repair safely, we strongly recommend contacting a professional technician.

Possible Causes

Extended use at maximum load, Blocked cooling vents, Partially shorted windings, Failing motor bearings

Safety: Stop use and remove the battery to allow the unit to cool.

Clean vents: Brush or blow out dust from all motor cooling vents.
Reduce load: Avoid continuous heavy-duty use; allow cool-down periods.
Monitor operation: If the smell recurs quickly under light use, the motor is likely failing internally.
Resolution: Replace the motor assembly before it fails completely and damages the control PCB or battery.

Hard 4/5

Motor Assembly

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