Question about Bosch Factory - Reconditioned 7/8" SDS - plus Rotary Hammer 11224VSR

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Sparks coming off brush

Heavy sparks off armature

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#1 Check your brushes & brush springs - you will have to remove the switch handle completely to access both brushes
#2 Visual of the armature - is it black / burnt or does it have raised segments?
Most likely it will need an armature if it has run for any length of time with bad brushes.
The armature comes out the front of the motor housing so you need to remove the gearcase to access it. Armature 2610003331 for Bosch Power Tool eReplacement Parts Carbon Brush Set
sparks coming off brush - 23910152-1tmh4chmwaodqgbdv43dd3kn-3-0.gif

Posted on Mar 14, 2015

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I have a porter cable pancake compressor 135 and it's sparking and smoking . What do you think it is?


Heavy sparking at brushes indicates shorted armature or short in field. Examine commutator bars, should look dark gray to black but very smooth. If scratched or pitted most likely end of life. If not too bad could be weak brush springs or worn brushes. Brushes should be at least 1/2 to 3/4 in in length. If commutator and brushes good , suspect field. Good luck

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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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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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1 Answer

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Sparking on the armature when running is normal in electrical tools. It should be small sparks with little intensity. If they are heavy arcs and the case gets hot then there is a problem with brushes, armature shorting or field winding shorting out or excessive dust and dirt on the armature.

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1 Answer

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Most of the time sparks in these tools come from where the brushes make contact with the armature. Some causes for sparks are: The brushes are worn down to where they don't make firm contact with the armature. Brush springs overheated and no longer push the brush down on the armature. The comutator on the armature is damaged and causes the brushes to spark excessivly. You can take it apart and try to find which parts are hurt but I don't know if any Clarke Power Products parts are still available. The company went out of business around 2009 so you'd have to find someone with left over parts. It may be easier to buy new and go with a name brand and new warranty.

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1 Answer

The compressor motor is getting hot, I removed the cover and one of the brushes is shooting sparks when the motor is turned on, the brushes seem to have plenty of pad left and seem to be aligned properly...


If there were a problen with the field or the armature, both brushes would make fire(look at both sides of each brush for spark). Sparking is normal, however heavy blue fire would indicate problem. When one brush is making unusual sparks I would suspect that the spring applying pressure to the brush against the armature has failed. Look at both brush springs and see if there is a color difference or feel the pressure that the springs are exerting. They should be equal. You can push on the brush slightly with wood or plastic tool. To see if there is an improvement. Replace parts as needed. Test the motor with amp meter and compare to amp rating on plate to be sure that there is not a problem with motor. If amp draw is slighly high, check for tight bearing, leaking head gaskets/reed valves or leaking checkvalve at the tank. Good luck.

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Makita LS1221, started heavy sparking from both brushes with greatly reduced speed. Brushes are ok. I'm assuming it is a shorted winding on either the armature or stator, how do I determine which...


you need to make sure the brushes move freely in the tubes and if they do I would suspect the armature is bad. LOOK for discoloration in the commutator thru the brush tubes.

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1 Answer

Replaced armature and brush's and there is alot of heat and spark and it starts slowing down?


Unless somewhat preformed, brushes have a tendency to arc like crazy and can produce heat and even smoke. I would remove the brushes and use a fine 'keyhole' type file to give them a little inside curve so they have better contact to start with.

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The 6865 has a high rpm AMTEK Lamb motor, Brushes will seldom solve the problem at this stage.
Once the sparking and burning starts the conectiion between the brush and commutator is arcing and burning. If the sparks are blue, save your time.
A good service tech will run in brushes with a seating stone and a low voltage setup to allow new brushes to seat, but this is generally best accomplished on heavy duty , lower rpm motors.
IF YOUR ARMATURE IS SCRATCHY LOOKING OR WORN LIKE AN APPLE CORE,OR THE SEGMENTS ARE NOT PARALLEL IN THE SPACING YOU WILL NEED A NEW MOTOR.

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3 Answers

My Dewalt chopsaw is loosing power and sparks heavy in brushes


I worked at a tool rental center while attending college and learned to repair tools such as yours. Damage to the armature occurs mostly during low power situations or overloading the motor. The damage is usually visable. Notice burned looking copper windings or commutator bars. You can test with growler or meter. We would turn the commutator on an armature lathe to true the surface of the bars. If the commutator is not perfectly round the brushes will bounce thus cause the sparking that you see. Also you must clean the groves between the bars with a blade to clean out all metal filings that can cause short between bars. (Broken hacksaw blade ground to fit the groves will work fine)Sanding with sandpaper may not be perfect enough to stop sparking assuming the armature is not shorted. Moisture will not effect the brushes, and sanding them square is ok but you can put the curve back by cutting fine sandpaper into strip and wraping it around commutator and insert brush into holder against sandpaper. Not necessary thou because all new brushes are square. New brushes however will increase the tension of the brush against the commutator preventing bounce due to new spring and longer carbon. Good luck enjoy

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