Festool of 1010 burning

[Larsb]

Hi, my OF1010 is throwing lots of sparks, I’ve changed brushes and polished the “Collector”
It’s sparking more than ever. What else might be the problem? Thinking about changing the bearings is that the way to go?
Attaching vid of both it running and the collector

 

[Larsb]

Guess the videos are to big, anyway it is throwing sparks from the area around the brushes.

 

[usernumber1]

'collector'? maybe you meant commutator

could be cracked armature, uneven commutator, not enough spring pressure on the brushes or a lot of other things

here's a handy guide
https://evmc2.wordpress.com/wp-content/uploads/2013/05/brushwearguide.pdf

 

[woodferret]

It'll spark more initially as the brushes conform to shape.

 

[Crazyraceguy]

I haven't had to deal with it on any of my Festool motors, but woodferret is probably right. Most of the brushes I have ever replaced were not formed to the shape of the commutator. You will likely get more sparking, quicker wear (initially) and maybe even a slightly different sound. Sometimes you can get that Ozone electrical smell too.
As the break-in, this goes away.