How to Replace a Table Saw Motor Brush Set

 

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This DIY repair guide explains how to replace the motor brushes in a table saw drive motor. The motor brushes transfer electricity to the motor armature to turn the motor shaft. As the motor brushes wear out, the drive motor runs weakly or won't start at all. Replace worn motor brushes with the manufacturer-approved replacement part.

Repair difficulty:
     
Time required:

Less than 45 min.

Part Required

  • Drive motor brushes

For manuals, repair guides, and specific part recommendations, enter your model number.

Tools Required

  • Slot screwdriver
  • Socket wrench set
  • Pliers
  • Wire cutter
  • Wire nut
  • Wire stripper
  • Cardboard for floor padding
  • Work gloves

Before you begin

Wear work gloves to protect your hands.

Instructions

 Warning: Undertaking repairs to appliances can be hazardous. Use the proper tools and safety equipment noted in the guide and follow all instructions. Do not proceed until you are confident that you understand all of the steps and are capable of completing the repair. Some repairs should only be performed by a qualified technician.

How to Replace Table Saw Carbon Motor Brushes

Step 1: Shut off the electricity

Unplug the table saw’s power cord from the wall outlet.

Step 2: Remove the blade guard

Raise the blade to its highest cutting position.

 

Push the red button on the blade guard and lift off the blade guard assembly.

Step 3: Remove the table insert

Pry out the table insert by inserting a slot screwdriver into the large hole in the table insert.

Step 4: Remove the riving knife and anti-kickback pawl

Loosen the blade tilt-locking knob.

 

Tilt the saw blade to a 45-degree angle and tighten the blade tilt-locking knob.

 

Remove the riving knife locking knob and washer.

 

Remove the riving knife, mounting plate and the anti-kickback pawl.

Step 5: Remove the saw blade

Loosen the blade-tilt locking knob and tilt the blade to a 90-degree angle.

 

Use the 2 wrenches supplied with the table saw to loosen the blade arbor nut.

 

Remove the arbor nut, outer flange washer and saw blade from the arbor.

Step 6: Remove the table saw support stand

Flip the table saw upside down onto a surfaced protected with cardboard or other padding.

 

Release the 4 table locking levers that secure the table saw to the support stand and remove the table saw support stand.

Step 7: Disconnect the drive motor wires

Release the 3 green ground wires from the ground wire bracket.

 

Remove the On/Off switch cover mounting screws and pull off the On/Off switch cover.

 

Using a wire cutter, cut the white wire at the base of the wire crimp.

 

Pull the black drive motor wire off the reset switch.

 

Using pliers, squeeze the sides of the strain relief on the motor wire cord attached to the On/Off switch box cover and pull out the strain relief.

 

Pull the motor wires out of the On/Off switch box cover. 

Step 8: Remove the drive motor

Rotate the hand wheel to lower the motor to the lowest position.

 

Remove the 4 motor mounting bolts and brackets.

 

Pull out the motor.

 Tip: On some models, you can replace the motor brushes without removing the drive motor. Skip this step to remove the brushes without removing the drive motor.

Step 9: Remove the motor brushes

Use a slot screwdriver to unscrew the brush caps and then pull out the motor brushes.

Step 10: Install the new motor brushes

Insert the new brushes into the motor and reinstall the brush caps.

Step 11: Reinstall the drive motor

Position the drive motor in the saw.

 

Reinstall the 4 motor mounting bolts and brackets.

Step 12: Reconnect the drive motor wires

Push the motor wires into the On/Off switch box cover and reinstall the strain relief.

 

Connect the black motor wire to the reset switch.

 

Use the wire strippers to strip 1/4-inch of insulation from the white wire ends and then use a wire nut to connect the white wire ends.

 

Reinstall the On/Off switch cover, using the mounting screws.

 

Reconnect the 3 green ground wires to the ground wire bracket, using the mounting screws.

Step 13: Reinstall the table saw support stand

Position the support stand on the saw base and lock the levers to secure the stand to the saw base.

 

Flip the table saw upright.

Step 14: Reinstall the saw blade

Rotate the hand wheel to raise the motor to the highest position.

 

Position the blade on the arbor and reinstall the flange washer and arbor nut.

 

Firmly tighten the arbor nut.

Step 15: Reinstall the riving knife and the anti-kickback pawl

Loosen the blade-tilt locking knob.

 

Tilt the blade to 45 degrees and then tighten the blade-tilt locking knob.

 

Reinstall the riving knife and anti-kickback pawl.

 

Reinstall the mounting plate.

 

Reinstall the washer and riving knife locking knob.

 

Firmly tighten the riving knife locking knob.

Step 16: Reinstall the table insert

Push the table insert back into the top of the table.

Step 17: Reinstall the blade guard

Loosen the blade-tilt locking knob, tilt the blade to 90 degrees and retighten the blade-tilt locking knob.

 

Push the red release button on the blade guard, reinstall the blade guard assembly on the riving knife and then release the red button.

Step 18: Restore power

Plug the table saw into the electrical outlet.

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