Why is my Power Tool Smoking and Sparking?



Posted: Friday, July 30, 2010

by Mallory Kramer
M&M Tool and Machinery

Seeing smoke or sparks flying out of your power tool is certainly not a normal nor desired behavior. Despite the scare, though, of a fireworks display breaking out of your power drill, there is a bright side amidst the chaos. Firstly, there are really only two places on a power tool where one might find said smoking or sparking action: either from the dust vents or from the switch assembly. Knowing this, and knowing where the smoke or sparks are coming from, helps us determine exactly where our problem is which puts us only a few steps away from a completely revived power tool.

To begin, if you experience any sparks or smoking form the ventilation points on your tool, there are just three scenarios to consider: One, your armature is bad. Two, your field is bad. And three, both your armature and field are bad. In either case, a bad field or armature is most likely the result of your having overheated, over-loaded, or in any other general sense, misused or abused the tool. You see, although many of us like to believe that our power tools are invincible, they are only designed for certain applications and with certain capacities. If we force them beyond these limitations, there is a very good chance that we will destroy one or several of the tool's major components. Ultimately though, in the event of a bad field or armature, one or both of them must be replaced.

Next, if said sparks or smoke are coming from your switch assembly, there is really only one way to interpret this problem; plainly, your switch is bad. In this scenario, your switch's present state of "badness" was likely caused by a shortage in the assembly which, in turn, was most likely caused by moisture damage to the switch, or slightly less likely, by overheating in the tool. In either case the switch must be replaced.

Determinimg whether the bad-boy behind your suffering power tool is your field or armature is as simple as checking their assemblies for heat damage. Heat damage will appear as any kind of colorful or dark discoloration, or like melting, charring, or burning of the armature's and field's wiring, wiring insulation, or assembly. Any heat damaged component will require fast replacement. While checking the field and armature, you may also want to look at the armature's commutator. If the bars do not form a smooth and complete circle it may cause the brushes to jump around and spark. This form of damage, however, although equally bad and equally needing of replacement, is likely not today's culprit. Also be aware the heat damage to the field and armature generally occurs simultaneously i.e. if one is damaged it's likely the other is too. If you catch armature damage early, you may sometimes prevent it from spreading to the field, but if your field is damaged, your armature is pretty much out of luck.

So, in short, be good to your power tools and if you should experience smoke or sparks emitting from them, a simple parts replacement for any heat damaged component is all the doctor will order.



For over seventy years M&M Tool has been the ultimate resource for power tool parts and power tool repair. With thousands of replacement parts on-hand from Dewalt parts to Makita parts, and through providing replacement parts and service to all the woodworking products, machinery, and power tools they sell, M&M Tool is the utmost authority in power tools, tool parts, and power tool repair.
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