Sounds like the motor if runs ok with motor disconnected, if the brushes wear down and are not caught early they can spark and overheat and damage the armature. There is a slim chance the excess carbon dust from the old brushes around the casing and brushgear can cause enough tracking to trip an rcd, its worth blowing the dust from the motor to see if this rectifies the fault. Cheers
Kenjo, May 2013