Brushes sparking too much - Homelite Consumer Products 9.0 Amp, 14 In. Chainsaw

Sparks and smoking from an air compressor after installing new brushes could indicate a problem with the brush fit or alignment, or with the armature.
Here are some possible causes and solutions to try:

1. Brush fit: The brushes may be too long or not fit properly, causing them to stick and spark. Try removing the brushes and inspecting them for proper length and fit. If necessary, trim them down or replace them with the correct size.
2. Brush alignment: The brushes may not be making proper contact with the armature, causing them to spark. Try adjusting the brush holder or armature to ensure proper alignment.
3. Armature issues: If the brushes and holder are properly aligned, the problem may be with the armature itself. It could be worn or damaged, causing it to spark and smoke. In this case, the armature may need to be repaired or replaced.
4. Spring pressure: If the brush springs are too strong, they could be putting too much pressure on the brushes, causing them to spark. Try replacing the springs with lighter ones to see if this resolves the issue.

Note: It's important to use the correct type and size of brushes for your specific air compressor model. Using generic or incorrect brushes could cause damage or safety hazards.

As with any brushed electric motor both brushes should be changed, it is not good practice to have different lengths of brushes.

possibly not as sparks can be from low brush length or the armature needs a clean up
all brushed motors spark when they run and normally it is a small blue spark the full length of the brush and contained under the brush
If it is a harsh arc like spark then the motor should be looked at by an appliance repair shop

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.

Squealing is usually associated with bad bearings. Sparks from the brushes is being caused by the motor pulling harder than usual because of the bad bearing. Sparks come from the carbon being burned off the brushes. I'd replace both, brushes are inexpensive and will make the tool work better and longer.

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.

if brush and spring are in good shape you have a major problem;
spark on 1 brush : stator are bad
spark on 2 brush: check both rotor and stator for damage

Hi kglove...
You will have sparks for quite a while until the brushes get the curve of the armature worm into them. The sparks are normal, the sparking should not affect the armature.
Please take time to rate me

you have a problem with worn brushes or the armature might be failing. UNPLUG the tool and remove the brushes to check their condition length and look at the face of the brush for any unusual wear. Then look into the brush tubes themselves and slowly rotate the armature for discoloration/raised commutator bars.

Check for a weak/collapsed spring on the sparking brush. Also check the brush holder for any interior debris which might impede proper brush movement. Do both brushes spark? There should be a fine line of spark at the brush contact to the commutator normally. Make sure the motor tuns easily, as a bad bearing can cause sparking due to overload conditions. Hope this helps!