Sparks are coming from the rear air vents of my Craftsman 12 amp reciprocating saw. I checked the brushes and they have about 3/4" of the carbon remaining. Can someone identify the problem.
Thanks in advance.
First, I'd take the handle off again and remove the Brushes so you can get a better look at the armature's commutator. Check to see if any of the copper sections of the commutator are burnt, missing or if there are excessive gaps in between the sections. Typically this is the problem with the symptom you're having.
Otherwise, check for any wires that may be bare and touching each other or possibly rubbing against the motor or moving parts. Hopefully this will get you started.
I can see the brushes making contact with the commutator and sparks flying. The commutator copper is very dark in color. Almost black. I'm assuming the teeth should be copper in color, like a clean copper plumbing pipe. And I assume it could be cleaned in a similar fashion. The problem is I cannot figure out how to get the tool apart since there are no fastener heads exposed, as far as I can see. (See photo)
I'll do some research to find out how to exactly to disassemble the case/housing, as I've never had my hands on this model before.
Are you able to remove the rubber insulator? Typically it's removable and once free, there should be screws recessed in the body that hold the halves together.
It does seem like the armature needs to be dressed/cleaned; once you get to the armature this is pretty simple to perform.
