How to Replace the Motor Brushes on a DeWALT Table Saw

Does your table saw not turn on? Are there sparks coming from the motor? You might need some new motor brushes. There are two motor brushes in your saw's motor. The brushes are made of carbon and have a lead wire and spring attached to them. The brush conducts electricity to the armature through the commutator. Because the brush is in constant contact with the rotating commutator, it will wear down with use and need to be replaced.

A worn-out brush may not contact the commutator, which will prevent the saw from turning on. Sometimes a worn brush will make weak contact, which can cause excessive sparking from the armature. This can also be a symptom of a damaged armature, so you’ll want to carefully inspect that as well.

Let's get started.

REMOVING THE MOTOR BRUSHES   1. Unplug the saw.

a. Disconnect (unplug) the saw from its power source.

  2. Adjust the saw blade.

a. Lower the blade as far as it can go by rotating the blade-height adjustment wheel.

b. Bevel the blade to 45-degree angle.

  3. Position the saw.

a. Rotate the saw onto the cord side (to expose the motor and brushes).

  4. Remove the motor brushes.

a. Use a flat-head screwdriver to unscrew and remove the brush caps.

b. Remove the motor brushes from the brush holders.   INSTALLING THE NEW MOTOR BRUSHES

  5. Install the motor brushes.

a. Install the new motor brushes into the brush holders.

b. Compress the brush springs into the holders and hold the brush in place while re-installing the brush caps.