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DeWalt DCS380 Motor Brush Replacement

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This guide details replacement of the upper motor armature containing the brushes and main power connectors.

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  1. DeWalt DCS380 Motor Brush Replacement, Removing shoe and boot.: crwdns2935265:01crwdnd2935265:01crwdnd2935265:01crwdne2935265:0

    • Remove the battery before disassembly.

    • Remove the shoe by pressing the yellow button on the left side of the hand grip.

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  2. DeWalt DCS380 Motor Brush Replacement: crwdns2935265:02crwdnd2935265:01crwdnd2935265:02crwdne2935265:0 DeWalt DCS380 Motor Brush Replacement: crwdns2935265:02crwdnd2935265:02crwdnd2935265:02crwdne2935265:0

    • Remove the two M8x18mm T20 bolts from the front plate.

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  3. DeWalt DCS380 Motor Brush Replacement: crwdns2935265:03crwdnd2935265:01crwdnd2935265:01crwdne2935265:0

    • Pull the front of the grip while holding the saw body in place.

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  5. DeWalt DCS380 Motor Brush Replacement, DeWalt DCS380 Grip Disassembly: crwdns2935265:04crwdnd2935265:01crwdnd2935265:02crwdne2935265:0 DeWalt DCS380 Motor Brush Replacement, DeWalt DCS380 Grip Disassembly: crwdns2935265:04crwdnd2935265:02crwdnd2935265:02crwdne2935265:0

    • Remove the battery before dissasembly.

    • Remove the M3x16mm T10 screw from the back of the grip. Keep it separate from the rest of the grip screws

    • Remove the six M3.63x19 T15 screws from the grip.

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  6. DeWalt DCS380 Motor Brush Replacement: crwdns2935265:05crwdnd2935265:01crwdnd2935265:03crwdne2935265:0 DeWalt DCS380 Motor Brush Replacement: crwdns2935265:05crwdnd2935265:02crwdnd2935265:03crwdne2935265:0 DeWalt DCS380 Motor Brush Replacement: crwdns2935265:05crwdnd2935265:03crwdnd2935265:03crwdne2935265:0

    • Remove the top half of the grip.

    • Turn the saw over and locate the power connectors to the motor.

    • Use needle nose pliers to remove the spade connectors. Take care not to grab the wires on removal, only the end of the spade terminal.

    • Note the polarity for the power connectors and be sure they are not reversed on reassembly.

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  7. DeWalt DCS380 Motor Brush Replacement, Motor Brushes: crwdns2935265:06crwdnd2935265:01crwdnd2935265:02crwdne2935265:0 DeWalt DCS380 Motor Brush Replacement, Motor Brushes: crwdns2935265:06crwdnd2935265:02crwdnd2935265:02crwdne2935265:0

    • Remove four M8x32mm T20 bolts from the base of the gearbox.

    • Pull the gearbox and motor out of the center housing.

    crwdns2913378:0crwdne2913378:0

    Hi,

    I am trying to reassemble the magnetic motor case back onto the gearbox; however, it isn't going down far enough and there is a 1/2” gap between the case and where it needs to mount into the aluminum. Any tips?

    John Chestnut - crwdns2934203:0crwdne2934203:0

  8. DeWalt DCS380 Motor Brush Replacement: crwdns2935265:07crwdnd2935265:01crwdnd2935265:02crwdne2935265:0 DeWalt DCS380 Motor Brush Replacement: crwdns2935265:07crwdnd2935265:02crwdnd2935265:02crwdne2935265:0

    • Remove three M8x18mm T20 bolts from the back of the gearbox.

    • Pull the motor armature out of the casing.

    • Note which side the power terminals are on. They will need to face the same way during reassembly.

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  9. DeWalt DCS380 Motor Brush Replacement: crwdns2935265:08crwdnd2935265:01crwdnd2935265:02crwdne2935265:0 DeWalt DCS380 Motor Brush Replacement: crwdns2935265:08crwdnd2935265:02crwdnd2935265:02crwdne2935265:0

    • Remove two M3.63x60mm T10 bolts from the inner edge of the motor case.

    • Pull the brush housing off the top, leaving the bottom half in place.

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  10. DeWalt DCS380 Motor Brush Replacement: crwdns2935265:09crwdnd2935265:01crwdnd2935265:03crwdne2935265:0 DeWalt DCS380 Motor Brush Replacement: crwdns2935265:09crwdnd2935265:02crwdnd2935265:03crwdne2935265:0 DeWalt DCS380 Motor Brush Replacement: crwdns2935265:09crwdnd2935265:03crwdnd2935265:03crwdne2935265:0
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    Tweezers
    $4.99
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    • This step is for reassembly of the motor.

    • Use tweezers to unload the springs from the new set of brushes.

    • Pull the brush heads back as far as the casing will allow.

    • Reload the springs after the armature has be re-seated.

    • Do not force the armature into the case. With all the brushes pulled back, it should slide in smoothly. Forcing the armature past the brushes can damage them or render them inoperable.

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To reassemble your device, follow these instructions in reverse order.

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Jonathan Hicks

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752 crwdns2915208:0crwdne2915208:0

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Eastern Washington University, Team S2-G5, Munoz Winter 2019 crwdns2935289:0Eastern Washington University, Team S2-G5, Munoz Winter 2019crwdne2935289:0

EWU-MUNOZ-W19S2G5

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Spot on perfect directions, thank you very much.

Kwalline - crwdns2934203:0crwdne2934203:0

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