Question about Dewalt Chop Saw D28700

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Armature is shorting out, throwing sparks out rear cap/ has new brushes (thought that was problem / shows small burnt area on armature / i cannot figure out how to remove armature / I stripped saw down to the armature but cannot get any further than the armature still in saw arm / parts breakdown shows snap ring but I cannot get to it.

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You have to pull on it to remove it or
use a punch and hammer on the end of armature(gear side)be careful to not damage teeth if you want to reuse it

Posted on Feb 22, 2014

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Posted on Jan 02, 2017

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SOURCE: My Dewalt chopsaw is loosing power and sparks heavy in brushes

I worked at a tool rental center while attending college and learned to repair tools such as yours. Damage to the armature occurs mostly during low power situations or overloading the motor. The damage is usually visable. Notice burned looking copper windings or commutator bars. You can test with growler or meter. We would turn the commutator on an armature lathe to true the surface of the bars. If the commutator is not perfectly round the brushes will bounce thus cause the sparking that you see. Also you must clean the groves between the bars with a blade to clean out all metal filings that can cause short between bars. (Broken hacksaw blade ground to fit the groves will work fine)Sanding with sandpaper may not be perfect enough to stop sparking assuming the armature is not shorted. Moisture will not effect the brushes, and sanding them square is ok but you can put the curve back by cutting fine sandpaper into strip and wraping it around commutator and insert brush into holder against sandpaper. Not necessary thou because all new brushes are square. New brushes however will increase the tension of the brush against the commutator preventing bounce due to new spring and longer carbon. Good luck enjoy

Posted on Dec 18, 2008

  • 1 Answer

SOURCE: Metal chop saw blows breaker

Is there anything else running while you are cutting? If not is the breaker 15 amp or 20 amp. If its 15 amp, I would change it to a 20 amp breaker. Make sure the wires are thick enough to handle the extra load. If this isn't the problem check the cord from the saw to the outlet.

Good luck!!

Posted on Aug 23, 2009

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The BDF452HW has a carbon brush motor - and they do eat up brushes quickly. The brush set number is CB440 - they are replaceable by removing the 2 screws on the rear cap, the connectors snap over the brush holder - take care not to bend the brush holders when changing, they are just thin brass.
If the tool is 'ticking' or 'grinding' when it spins check the condition of the armature before you install new brushes - the copper commutator should not look burnt or have raised segments - this is also a common repair on this tool. Replacing the armature is a fairly inexpensive and easy fix - you must split the entire clamshell housing to access this - be sure to fit all the components securely back into their slots or you may tear all the fan blades off the armature when you try and run it.

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Often a collapsed brush spring will cause this - remove the brush caps and inspect the brushes - if the brushes are short >1/4" or the springs are broken or weak you can try just replacing the brushes. With the brushes out you can use a flashlight and look through the tube to inspect the armature. The copper commutator should not look scarred or burnt - if it is you most likely will need an armature.

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The armature comes out the front of the motor housing so you need to remove the gearcase to access it. Armature 2610003331 for Bosch Power Tool eReplacement Parts Carbon Brush Set
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Forgive me as I'm not too educated on the configuration of this saw but when I heard you mention armature replacement it made me think....are there armature brushes that are worn out. I know a lot of my angle grinders spark, get real hot, and smells like burnt plastic when brushes are worn out. Are there brushes on this saw? Just a thought.

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Sounds like you have a bad rear armature bearing.
Remove the end cap on the motor and the 2 carbon brushes.
Remove the 4 screws that hold the motor housing to the frame and pull it straight off.
Most often the bearing heats up enough to ruin the rubber boot that sits over the bearing as well as the motor housing itself. Check to ensure the armature is not burnt

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1 Answer

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Brushes can have very small, blue sparks coming off them and be OK. If it's bad enough that you can hear, smell or see excessive sparking it can be caused by: a) The brushes are worn down or the springs are collapsed and the brushes are not making good contact with the armature. b) The armature contact (commutator) is damaged or there is a short in the armature windings. Replace the brushes or armature as needed. I can't give part numbers as your problem is listed in cut-off saws and grinders but your model number is for a rotary hammer.

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Brushes arc for several reasons. If the spring over heated and lost its tension or the copper line from the brush to the cap broke/burnt off or the brush wore down too far to be pressed on the armature properly. The replacement brushes you need are Makita part number CB-124. If you still have exessive sparking after replacing the brushes you may have a bad commutator on the armature. The only way to fix that is to replace the armature, Makita part number 512831-0.

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My jigsaw stopped running. Judging from the sparks coming from around the armiture, my guess is the trouble has to do with brushes or worn armiture. The saw is not an expensive one so perhaps it's not...


Many times I clean the commutator with light sand paper and she come back to life. Take a brush out and sand the end off to clean it. Then fold a small piece of sand paper and push it down in the hole where the brush goes and rotate the motor by hand and clean the comm off. Good as new!

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