Question about Dewalt D28494N 7" and larger Electric angle grinders

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Sparking bruch the grinder is having ring spark and giving out smoke

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Most likely the carbon brush is worn out and need to be replaced.

Posted on Jan 15, 2009

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Posted on Jan 02, 2017

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You did not indicate whether or not you have compression now that you have changed out the gaskets and piston rings. If not, it seems to me that the problem could be a) cracked head or block, b) bad valve(s) or even c) a warped head.

Sorry for the bad news (if I am right).

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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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It sounds like the armature is shot. When the armature goes bad you will see excess sparking from the brushes.

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Grinder is giving out sparks from back and giving burnt smell


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Brushes. The brushes have worn down to the contacts or worse, to the springs.

The good news, brushes are inexpensive.

If you are mechanically inclined and comfortable dismantling power tools of medium to high complexity this is something you can do at home.

HOWEVER, if you have even the most minimal reservation, I would recommend bringing it to a shop so an experienced repair person can replace them. For example, if you need instructions on how to re-assemble planetary drive gears, bring it to a shop.

The procedure should be reasonably priced and quickly accomplished.

Best regards
Mike

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