This page is about problems encountered after fitting new carbon brushes in a washing machine. If experiencing these issues without having just replaced the brushes though some of this article (and links) may still help.
Motor is sparking
A small amount of sparking is normal. Small sparks may occur until the carbon brushes bed in properly. Little minute sparks are often present but as long as they are very small should not indicate a problem. However, if there is a lot of sparking, particularly if it is flashing or arcing around the commutator then the repair is no good and you should stop using the washing machine before it blows something.
Have brushes been fitted correctly
The first thing to check is have the brushes been fitted correctly? It should be impossible to fit brushes the wrong way these days. The brushes come inside plastic holders. The holders are keyed so that they will only fit in the correct motor and the correct way. However, if for some reason someone has taken brushes out of their holders and manually put new ones in then they can be put the wrong way around.
Also, if someone has fitted the wrong brushes and forced them to fit or removed the keying stubs then you need to fit the proper brushes for the motor in question.
A correctly fitted brush has the curved end of the brush trailing against the commutator (the copper segments). If fitted the wrong way round then only the tip of the brush trails against the commutator instead. This would cause a loud ratchety sound and excessive sparking or lack of power.
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If brushes are fitted correctly, but you still have excessive sparking, especially big flashes, this is caused by poor contact between the brush and the copper segments they run on. This is usually because the commutator (copper segments) is worn or there’s a major fault on the armature. There’s nothing you can do except replace the armature – but as most manufacturer’s no longer supply new armatures – the entire motor.
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In most cases now, new armatures can no longer be fitted and a complete new motor would be required. I would be cautious about buying an expensive motor unless you are very confident about the diagnosis and fitting.
Motor is making a strange noise
When new brushes are fitted there is a period of bedding in needed, during which time (especially on first running) they can make a loud noise as the motor turns. This noise should diminish within a minute or so and diminish more after several washes. As long as the motor isn’t sparking excessively it should be ok and they should bed in. The noise should be the same when the motor is running as when you turn the drum by hand. It is the noise of new brushes riding over the segments of the commutator on the armature which is always loudest before they bed in.
Motor making loud clicking noise?
If there is a discernible click on each revolution, then one of the copper bars on the commutator that they run on could be loose and slightly raised. In serious cases even missing. This can’t be repaired and a new armature or motor would be required. To test for this remove the motor from the machine and place a fingertip on the commutator (the copper part with small individual sections). Slowly rotate the armature from the end where the belt fits. See if you can feel if one of more of the copper bars is slightly raised or not. If so the motor needs replacing (if it’s economically viable).
DIY Repair tips
You shouldn’t be messing with washing machines unless you are experienced at repairing and maintaining things and know what you are doing around electrics. Here is some vital advice – 3 good pre repair tips | DIY Washing machine repair warnings: 8 things you should never do
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Uche says
Pls can i reshape the carbon brush before i fit it in?
Whitegoodshelp (Andy Trigg) says
It should be completely necessary, is it the wrong brush? A certain amount of smooth filing down may be ok but not on the curved bit that runs on the commutator. That needs to be perfectly shaped to make optimum contact or excessive sparking and burning will occur.
Andy says
I have fitted the carbon brushes and double checked them, they are in contact for sure but are sparking slighly, like a very small sparkler just on one side, its diminished after the first full wash but its still there slightly, could this just be the bedding in?
Andy Trigg says
Probably Andy. As I explain in the article small sparks are normal. When an engineer fits brushes they often help bed them in using a special comm stick but they should settle. If not try removing the brush and lightly cleaning it with fine emery cloth at the point where it’s sparking.
karen says
My husband is replacing the brushes on my bosch machine however, the motor is on the underside of the drum, how will I know if it’s sparkng at all?
Andy Trigg says
Hi Karen. The motor should be observed with the back panel off. However, some washing machines no longer have proper back panels, some have no access at the back and others just a small inspection hatch to allow access to the drum pulley.
A motor with newly fitted carbon brushes will often have a harsh high pitched sound for the first several washes until they bed in but if a motor is sparking seriously you should be able to tell from the sound. It will make crackling or grating noises as it turns. On tiled floors you can often also see sparks reflected just under the front of the machine.
Andy says
I just changed the brushes on my Bosch washing machine and when it’s on a fast spin that’s when I see blue flashes reflecting from the bottom of the machine is this normal? I’m sure I’ve put the brushes in correctly because the machine sounds perfectly normal on slower rotations and there’s no blue flashes!
Andy Trigg (Whitegoodshelp) says
Hello Andy. It all depends on how big the sparks are. If you can see them reflected it implies they are relatively big. As I describe in my article a certain amount of sparking is normal at first until they bed in. However the sparks I would describe as being nothing to be concerned with are very minute sparks. No more than a millimetre and usually quite even. If there is a problem, the sparking will normally cause noise. In other words it’s unusual for sparking to be bad enough to be a concern without making any new noise.
If the sparks are more like flashing, and there’s a lot of flashing then it implies the brushes are not bedded in properly. If they don’t settle down they could result in burning or in worst case scenario the motor could short out the electrics or even blow the PCB. If the armature itself is worn the brushes will never bed in. The motor would need replacing.
If concerned, remove them and inspect the face that runs on the armature. See if they have bedded in by looking at the surface to see if you can see how they have started to wear down to fit the armature. Sometimes there is evidence that they are starting to bed in but just one corner hasn’t touched the surface of the armature and is clearly still brand-new. If this happens it can create sparks. You could try gently sanding the surface of the brushes with some very fine emery cloth but you have to be very careful not to interfere with the curve that is designed into the brush so as it fits onto the armature itself.
You also need to ensure the brushes not sticking in the holder. If none of this works and you know you fitted the proper brushes it sounds as if the motor is going to need replacing.
Katrina says
Hi my machine is a new innex Indersit, washes ok but when the drum Goes around one way it’s quiet but when it goes the other way it’s making a noise like it’s scraping on something
Engineer came round I explained the problem he said because it’s new after a few washes it will be ok , still no better
Andy Trigg (Whitegoodshelp) says
Hello Katrina. Assuming the noise is coming from the motor it’s possible for one of the carbon brushes in the motor to be sticking or not bedded in properly which can cause sparking when the motor turns one-way. If it is still doing this after several washes you should get them back to fix it. Just double check that it doesn’t make the noise when you turn the drum by hand, if it doesn’t then the chances are it is when the motor is running that the noise is created.