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Exesive sparks on the brushes (Bosch GSB 16RE drill)

I overpowered my drill and now there are exesive sparks on the brushes.First I suspected the armature and changed it , still no joy, then I measured the fieldcoils and found it totally differend ohms and replaced it but still no good. Could it be that my armature got hurt by the broken field coils?Please HELP

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  • lorna_vanzyl Jun 17, 2009

    I have just ran it with no load and it was still sparking, but took it to repair shop -they tested the armature while I was there -no fault- I am still waiting for there answer thanks for reply



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If you used the drill any amount with a burned field coil there is a good chance that is has burned the new armature out.

Posted on Jun 11, 2009


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My milwaukee hammer drill spins when trigger is pulled but many sparks from where brushes are along with a lot of electric burnt smell.

Change the brushes. The brushes have worn into the armature. I have had the same issue and that can usually fix the issue. But if armature is too far gone, the drill may be D.O.A. and time for a new one. Christmas specials are all over the place at a lot of local places that sell tools. Get on line and shop around should you want to replace instead of repair.

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Does anyone have advice on what to check next if you've changed the brushes on a BHR202 and it still doesn't work?

Is there a Deep discharge protection connector on your powertool ????

The thirth small contact in the battery connector or only 2 contacts ?

If not then its an advise it must be modificated then you have only to break off a notch on the new modificated battery holder connector so it can be placed in the older not marketing technical modificated housing, and you have to change the switch and the battery connector , the differences are 091A. 643844-1 old batteryconnector (2 contacts) change into 091B. 644808-8
New modified batteryconnector (3 contacts with deep discharge protection it has a limit until a level)
088A. 650578-9 Switch old model (2 contacts) replace for a
088B. 638882-6 New modified switch (3 contacts )

What you need is even expensive by this model if you have a modified type with the 3 contacts to know what can be wrong else is remove the brushes charge you battery and measure it first if its full and take a multimeter measure tool between both brushholder measure and pull the trigger that must between give 16and 20 volt DC if the battery was good charged . next measure is ohms resist measure both brushes in the brushholders and measure for a few ohms from brushcontact to brushcontact throught the armature inside the machine.
if not a resistance to get measure through the armature without brushes if some object or parts was comming trough the ventilation of the machine between armature and brusholder then the brush beet not the collector anymore different things to look at .
26116694-xaq5q3decq2piqybkt2ddcrv-2-0.jpg Look also how the kind of wiring technik of the armature is different left is a old kind of armature that will last for 5 years or more its having thicker wiring and an other winding pattern instead of the modern kind of armatures from the last years from 2009 and later Johnson armatures by PANASONIC MILWAUKEE, MAKITA , this new armature has a lot of more power but its faster defect because of the to tight tolerance of heat dissipation and ventilation but thats most in time of inbetween 2 or 3 years worn by the great strength and light machine makes this rapidly abuse when it is going to slowly get gives a shrill sound then i know there is also not much power on , batteries are fast empty and no power left ( AND THE PROBLEM IS PEOPLE THINK THE BATTERIES ARE GETTING OLD no thats not the problem but the armature is it and as before its eating carbon brushes in between 1 month again so fast if its worked in daily use. ALWAYS REPLACE BRUSHES AND ARMATURE (thermical shortings not to see but to hear and measure) at the same time it isnt not so expensive as that you choose new batteries and the batteries work great on a other tool . if the machine has eating the brushes with the old armature left on picture nothing was happens and it last again in good condition but the power difference is great between the old and the new armatures of the brand Milwaukee 18V to compare this old was Milwaukee 18volt and right the same kind of new sensitive armature like Panasonic or Makita have used in their tools.

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Sounds to me your armature needs replacing. Basically brushes either work or don't work. some times you may get heavy sparking but that is the spring not pushing the brush on to the commutator. Loss of power and smoking usually armature if you use the drill in this state you may burn out the field coils as well.

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first measure of the batterie if its loaden ,only if the brushes are to short replace also anyway the armature and brushes BOTH . it is not good to switch only the carbonbrushes because of a marketing technical design concept because of the heat dissipation that playing tricks insite the armature and it is cheap made by Johnson
sometimes the half value compared to other brandnames.

Armatures are new designed in a short time

23465970-2oroqqetjko0hjqmfukebeah-4-0.jpgleft the armature of the old but same cdd 18 milwaukee no problems you can change only the brushes and its working again right the same modificated armature marketing technical a new design of this JOHNSON Armature (Johnson is also used in Panasonic powertools bv EY7441 ) it has much more force in the same armature but the heat dissipation plays tricks and if the brushes are to short replace anytime BOTH (the brushes and the armature look at the difference of the turns of the coil front right look the later design more and thiny wire on it more power force but a bad heat dissipation in about 2 or 3 years the brushes are on its end take by heavy work a more powerful tool its better longlasting then this machines Makita has oft a better armature but there are also posibillities in some tools.

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