Guide :Saws : 7 1/4" Magnesium "Mag 77" Wormdrive Saw With Twist Lock...

Sparking saw was notably sparking where the brushes make contact and tripping breaker. I changed the brushes but still sparking alot, the brushes I took out 1 was about 5\8 long and the other about 7\16 long. help thanks

Posted by jdm6 on Jan 17, 2009

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Sparking saw was notably sparking where the brushes make contact and tripping breaker. I changed the brushes but still sparking alot, the brushes I took out 1 was about 5\8 long and the other about 7\16 long. help thanks


Sounds like the stator is damaged. that is the shaft that the brushes rub on. unfortunately this usually means time to buy a new saw. since you really don't have much to loose, you can tear the saw apart and pull the stator shaft out and sand the copper area and smooth out any rough spots or nicks.Ultimatley you would want to chuck it up in a small lathe and turn it down a hair.this would ensure that you stay even all the way around. but most people don't have a lathe so just put it in a vise and take some 120 grit sand paper,preferably narrow strips about 1inch thick and start working your way around.
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Right at where the brushes contact the armature there is a great amount of sparking when I run the saw. What is the problem?


If you are seeing a lot of spark where the brushes contact the armature that meens that the brushes are low and need to be replaced. If the saw is new though that meens that the brushes have not broken in to the right seat yet. Good Luck
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I changed the switch and brushes. Still nothing. cord is new. help if u can>


Is the commutator (part the brushes push against) all gouged up? What about wire after switch? Also sometimes the plug itself does not make good contact. Pull the switch and move the plug around in the outlet while you have the switch pulled (Watch out it may turn on) Make sure that there is power at the outlet, and try a different outlet.Check all your connections. My guess is the cord.
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Skillsaw throws sparks when on - Skil 7 1/4" Magnesium "Mag 77" Wormdrive Saw With Twist Lock Model # SHD77M 72


Often a collapsed brush spring will cause this - remove the brush caps and inspect the brushes - if the brushes are short >1/4" or the springs are broken or weak you can try just replacing the brushes. With the brushes out you can use a flashlight and look through the tube to inspect the armature. The copper commutator should not look scarred or burnt - if it is you most likely will need an armature.
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SKIL MAG77LT 15-Amp sparking in the motor - Skil 7 1/4" Magnesium "Mag 77" Wormdrive Saw With Twist Lock Model # SHD77M 72


Check to see if you have a colapsed brush spring. When they get overloaded it heats the spring and they will colapse and not get good contact with the armature. The brush ce same width aould be hanging up a bit in the holder. Clean the brush holder with a points file and see if the brush travels enough to make good contact with the armature. Or the armature can be bad. It should have a nice even dark ring around it the same width as the brush. If it's pitted between two bars, a bar is missing, or it's discolored above and or below the normal wear line of the brush the armature can be bad.
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I have a 3yr old skilsaw SHD77M. I am seeing a lot of flah back from the brush and armature contact points. When I removed the brushes they were highly pitted and there is discoloration on the armature. While running there was also some smoke and the smell of burning. I filed the brushes to a clean surface since there was still about 1.5 inches left in the brushes but I am still see the same flash and it tripped a breaker this time. I am assuming this indicates a bad armature but I would like to verify before spending the money on one.


I think that you got it right. what I would do is take the armature out and take toa repair shop and ask them to put it on a growler. But after removing look for cut windings and raised commutator bars if either it is bad, also replace the brushes along with the bearings.
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