How to Replace the Carbon Motor Brushes on a DeWALT Chop Saw (Model D28715)

Saw chopping into your budget? It's time to face the fix. Whether you are a commercial contractor or a weekend welder, eReplacementParts.com provides the parts, procedures and facts you need to fearlessly fix what fails you.

There are two motor brushes in your saw's motor (one on each side of the armature). The brushes allow electricity to flow to the spinning armature. Because they are made of carbon, brushes will wear down over time (and need to be replaced). When a brush wears thin enough, the brush spring will no longer have enough pressure to hold the brush against the armature, and the motor won't turn on.

A brush that is nearly worn out will often create sparks on the armature (due to a slight gap forming between the brush and the armature). Sparks from the motor can also be caused by a bad armature. So, if replacing the brushes doesn't help, you may have more problems.

If the motor is overheated, the brush wires and springs will often become damaged. The overheated brush wires and springs will be burnt, and will no longer make good contact with the carbon brush.

This article provides step-by-step instructions for removing and installing the carbon motor brushes on a DeWALT chop saw (model D28715).

Let's talk chop.   REMOVING THE MOTOR BRUSHES [top] 1. Unplug the saw.

Disconnect power to the saw.

  2. Remove the motor end cap.

Remove the (2) screws securing the end cap to the field case.

Remove the end cap.

  3. Remove the motor brushes.

Use a flat-blade screwdriver to unscrew the plastic brush cap.

Remove the motor brush cap.

Remove the motor brush.

Repeat this step to remove the second motor brush.

  INSTALLING THE NEW MOTOR BRUSHES [top] 4. Install the motor brushes.

Slide the new motor brush into the brush holder.

Secure the motor brush with the brush cap.

Repeat this step to install the second motor brush.

  REASSEMBLING THE UNIT [top] 5. Reinstall the motor end cap.

Install the end cap.

Secure the end cap with the (2) screws.

Do-it-yourself repairs like these are easier than you might think: From lawn machines to cordless drills, kitchen mixers to outdoor grills. Our "how-to" articles walk you through each repair from start to finish.

So, doing-it-yourself means never having to do it alone.

Find your next fix here.   [top]