Trying to remove brushes on my Hitachi C10FSH MITER SAW. Removed caps on sides of motor housing with no problems. The brushes will not come out, scared to pull on springs to hard. Suggestions please!

There are a few things that can cause this:
1) Check the brushes - make sure they are not severely worn and make sure they travel freely down the brush tube & contact the armature well.
2) If the brushes are OK the problem is most likely the switch. Tools with a brake have a 2 pole switch - one set will be normally open and one set will be normally closed (Most switches have a diagram printed on them) Disconnect the leads (keeping track of where you removed them) and using a continuity tester check the switch - you should get a reading between the normally closed contacts and lose it when you pull the trigger. Most likely you will find you are not getting a reading on the normally closed side and that would be your culprit. Hitachi C12RSH 12 Sliding Dual Compound Miter Saw Parts

If your Bosch 3915 compound miter saw is making a grinding sound when it slows down, it could be an indication of a few different issues. Here are a few things you can try to fix the problem: Clean the saw blade: A dirty saw blade can cause the saw to make a grinding sound. Use a brush or compressed air to remove any debris or sawdust from the blade. Check the blade for damage: A damaged or worn blade can cause the saw to make a grinding sound. Check the blade for any chips or missing teeth, and replace the blade if necessary. Check the bearings: The bearings on the saw's motor and blade can wear out over time, causing a grinding sound. Try to move the blade side to side to check for any play or looseness. If the bearings are worn, they will need to be replaced. Check the motor brushes: The motor brushes on the saw can also wear out and cause a grinding sound. Check the brushes for wear and replace them if necessary. Lubricate the saw: Lack of lubrication can cause the saw to make a grinding sound. Use a lubricant designed for power tools to lubricate the blade and other moving parts of the saw. If none of these steps solve the problem, it's best to take your saw to a professional for repair. Grinding sounds can be an indication of serious issues, and it's important to address them before they cause further damage to your saw

If the brushes are stuck on your Hitachi c10FSH miter saw after you remove the set screws with a allen wrench, what I did was pull on the spring it will eventually break off or the brush will come out. If the spring breaks get a small screw driver with a fine point and try to break the brushes up,tap lightly as you do not want to damage the armature below, then get a vacuum and suck the pieces out , pick out the remaining pieces until every piece of the old brush is removed. By spinning the motor and looking into the hole where the brush goes into you can see if all the pieces have been removed. What happened is that you waited too long before servicing the brushes and they wore flat and got stuck inside, otherwise they should come out easily.

Try fitting a new set of brushes first otherwise it could be that it needs a new field coil.

On the sides of the motor housing there are two small, black screw caps about as big around as a dime. By removing those the brushes will come out. Most come out easily but if they are in very tight, be carefull not to strip out the screw driver slots. The caps are made of a hard plastic that breaks easily and if the slots are stripped out they are very difficult to remove.

brushes in the motor

After removing the black brush caps, take compressed air and blow any debris out. Next take a pair of needle nose pliers and gently pull the brush,,, ( you can use a moderate force). If it does not pull out you may need to remove the black vent cover adjacent and use a tiny screwdriver between the brush and the armature, as there may be a slight burr on the brush. Good Luck.

there is always going to be some sparking between the BRUSHES and the commutator. if it is excessive and loud or is really heating up the housing, there could be a crack in one of the brushes, the brush might be chipped or unevenly worn, or the brush holder itself may be burned cracked, or otherwise need to be replaced. they may LOOK okay but need to be pulled out to really know for sure sometimes. there is a small set screw in the housing that holds the brushholder in place.

while this could be the problem with the electric brake, it is more likely that there is a wiring connection loose, broken or burned inside the motor housing. it could be the switch but i dont believe the brake circuit runs through the switch on this model.

no the break needs ajusting

Take the unit off your saw. There should be a removable back side that will allow you to replace the coin battery inside the unit.

Good Luck!

Ben