How to Disassemble a Reducer Angle Grinder Makita 5030
Instructions for use, operation and repair, tips and tricks
An electric tool always stood many steps higher than a manual one. This is reflected in a number of indicators. Speed, speed and effectiveness of the action. Thanks to such data, these units are preferred. If you do not keep a record of professional work, then almost every owner in life has such electrical devices. The main ones: a screwdriver, a jigsaw, a drill and an angle grinder.
Each technique has its own advantages, but there is no need to exclude the possibility of breakage. Angle grinder is considered the most necessary unit. It acts quickly and is applicable to many materials. But the revolutions show the maximum that bribes each user. Before you start using it, it is worth understanding the principle of work.
How to understand the angle grinder? Understanding the principle of the entire system is not difficult. Power is supplied from 220 W, and then an asynchronous single-phase motor starts. To do this, use the “Start” button. There is a shaft that starts the device to work. One part of it is located outside the enclosure (to attach a disk to it). This is how the material is cut. Depending on the rotation, the force acting on the part changes. As a result of the action, it is the motor power that is important. If it is insignificant, then the device starts to warm up and malfunctions.
If high revs are required, then Boch is a good fit. This is a unique design where the manufacturer focused on the motor. And disassembling the angle grinder “Boch” is not so difficult in the event of a malfunction. Cost matters. High power is not observed in cheap models. The gear allows you to fix the angle of 90 degrees. To prevent frequent breakdowns, the case is made of shockproof materials.
Before disassembling the angle grinder, you will have to carefully study the level of breakage. The device includes:
- Two streams of air.
- Air deflector.
- Air distributor
- Radiator housing.
This system allows you to extend the life and evenly distribute the load. There are several air flows that allow for cooling. The main, additional and combined. Such a system is simple and does not require special care.
What tools are needed?
So, we take apart the “Boch” angle grinder. First, the tool is prepared:
- Electrical tester.
- Screwdriver in line.
- Pliers and tweezers.
- Insulating material.
- A brush that removes dust.
- Needle file and alcohol.
- Stripping paper.
- Special grease.
The brand of the device itself affects which kit will be used when disassembling. For example, before disassembling the Bosch angle grinder, you will have to take a special screwdriver. Because the manufacturer protects the heads of the bolts for fastening. But in the end, it’s not so difficult to unscrew them. There are enough nozzles on the main key, so there is no need to worry. Before you begin to make repairs, it is worth disconnecting the angle grinder from the network. This is the first security rule.
Malfunctions and how to understand them
There are symptoms that make it easy to understand that a breakdown has occurred. In addition, the devices are easily repaired with their own hands. The collector is fixed on the rotor and looks like several contacts coming one after another. They are erased due to the action. Angle grinder brushes are made of a material that quickly deteriorates. How to understand what needs to be changed? It’s simple: wherever the grate goes, sparks appear during the cutting period. It is also difficult to set the maximum speed when the part opens. If such a breakdown is observed, then the repair must be immediate, otherwise the damage will become serious.
To remove the brushes, you should pay attention to the manufacturer and model, because some are easy to clean, without disassembling the design. The plugs are simply removed, and on other units it is necessary to disassemble the back cover. Therefore, before disassembling the Makita angle grinder, it is worthwhile to understand where the brushes are located. This will eliminate unnecessary actions.
There are manipulations that are performed on any electrical unit, regardless of brand and manufacturer. The old brush is removed, its seat is wiped with alcohol, soot is removed. The process of fixing a new spare part is performed in the reverse order. The brush installed in its place has a small gap. But the maximum density is unacceptable. When this rule is not respected, the part quickly fails or the unit heats up when performing an elementary cut.
When the device is assembled, it is worth checking its functioning. Each user will notice that there is no spark, heating is not present. From these signs, it is clear that the launch is correct, and the movement of the disk is not disturbed.
Why does the tool not turn on?
Before disassembling the angle grinder (angle grinder), you need to be prepared for additional replacements inside. It also happens that it just does not start. Most often we have to talk about the minimum voltage. Therefore, in this situation, a current check is performed. Then you have to disassemble the case, check the wiring inside from the beginning to the feed. The whole procedure is performed in stages. If one part is in order, further damage is sought.
If there is a good signal, this version is excluded. The main part of all power tools has a speed control. It will have to be checked. To do this, the lever is moved to the “maximum” position. If the brushes are broken or there is no power supply to them, the unit will slow down or start up will be completely ruled out. Brushes should not be worn out, electricity supply must go to them in full. If there is any flaw, then the old parts are changed and the installation for start-up is checked.
What else could happen?
Sometimes the spindle lock button fails. It facilitates the process of replacing disks. A problem in this area occurs due to ill-treatment or the need to remove a clamped disc. Repair is not worth it. It is better to install a new part. In addition, often not turning on occurs for other reasons (for example, the brush fuses). Even such difficulties are caused by the bearing clamp.
Here is the gear, and such a breakdown happens often. Therefore, the question arises of how to disassemble the reducer angle grinder. And the kind of part depends on its power. Allocate:
The desired speed is gained at a power of 1100 watts. According to experts, the second option has more strength and a long service life. But the installation of such a gear occurs on large angle grinders, which are used on an industrial scale. How does an inexperienced person understand that the gearbox is broken? The first sign is a change in sound when cutting a part. This is relevant at startup. So, there is a rattle and knock in places. In no case should you continue working, otherwise a more serious breakdown will occur. After that, it is worth analyzing the tool, assessing the damage to the gearbox. Then you have to change the failed part.
What you need to know before repair?
Before you begin the analysis, you will have to really assess the situation and the alleged damage. It is not necessary to analyze everything. It happens that after cutting it was packaged in a box, and the next day it stopped functioning. This can happen because she has accumulated dust. Any permissible error during operation carries with it some kind of breakdown. Therefore, it is necessary to restore the entire period of activity until a malfunction occurs.
Before the first launch, it is worth visually evaluating:
- The integrity of the wire and the performance of the outlet.
- Dustiness of the performed actions (implies internal filling), periodically cleaning is done.
- If the room is humid, then during the use of the unit there will be oxidation of some contacts. This will make normal operation impossible.
- Violation of operational rules will lead to failure.
There is no need to rush. It is better at the first stage to figure out what is the reason for this phenomenon, and only after that to disassemble the device.
How to Disassemble Makita Angle Grinder. Vdiweb.Ru
How to disassemble a Makita angle grinder
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Anchor. A rotating element of an electric motor containing windings.
The collector is a place at anchor, to which our client remains windings. It looks like a series of plates isolated among themselves.
A stator is a fixed part of an electric motor containing windings.
Brushes. Carbon parallelepipeds supplying current to the collector.
Reducer. A mechanical device for transmitting rotation with power changes not rotational speeds.
The most popular tool in everyday life after a drill is an angle grinder or, as they call it more often, an angle grinder. Angle grinder is used for cutting metals, wood, concrete, grinding various surfaces, cutting openings, doors, niches. If there is an angle grinder, then it can always be used and it is especially offensive when it ceases to function normally, jerking, twitching, burning smell.
The angle grinder is all arranged in the same way: the elongated housing in which the engine and gearbox are located, a handle and a protective casing are screwed on the side.
On the body of the angle grinder is a sticker with the source data. Here you can find both the personal number of the angle grinder and the supply voltage. 230 V. Here we mean the maximum allowable voltage in the network. The current frequency in the network is 50 Hz. The consumption current is 5 A. The power consumed from the network is 1100 W, it is obtained as the product between the voltage (220 V) and current (5 A) multipliers. Frequency disk rotation, established on Angle Grinder. 2800-11000 rpm. The anchor itself rotates at a faster speed than the disk itself. It is on this angle grinder that step-by-step regulation of the rotation speed is possible. The disk mounted on an angle grinder has an outer diameter of 125 mm, the mounting nut of the disk has an M14 thread.
A household tool designed for a phase voltage of 220 V has an armature winding and a stator winding. Energy is transferred from the network to the anchor using graphite brushes. The voltage from the network is supplied to the switch, which is mechanically connected to the power button of the angle grinder. The stator winding consists of two halves not electrically connected. An anchor winding consists of many windings, but at any moment in time, the brushes connect only two windings of the armature.
When you turn on the angle grinder, current is supplied to the input of half of the stator winding, the output of the stator winding is connected to the brush holder into which the brush is inserted using a spring. The brush transfers current to half of the armature winding, on the other hand, the other brush receives current and through the brush holder transfers current to the other half of the stator winding. Current entered and exited the angle grinder. If the entire electrical circuit is operational, then the armature will begin to rotate.
Reverse, i.E. A change in the direction of rotation of the disk can be done if you swap the wires going to the brushes from the stator windings. Just disconnect the wires on the brushes and swap them.
At the end of the case, an angle grinder is located a red wheel for step regulation rotational speeds anchors and screw for removing the casing.
In this form, the angle grinder the brushes themselves are located inside the case and there is no access to them, but the developers simplified the replacement of the brushes when removing the casing. After unscrewing the screw, the plastic plate is removed and the outer casing is shifted towards the cord, exposing all the insides, including the brush holders.
The speed control mechanism is electronic. The whole circuit is filled with epoxy and only the speed wheel and the radiator are out. What is hidden inside. Trade secret of the company. When the unit fails. Speed ceases to be regulated, but remains at the maximum level. In any case, you should not despair, and in turn with the angle grinder you can turn on the most ordinary dimmer. Dimmer. With it, you can adjust the speed of any AC alternator motor, the main thing is that the engine power does not exceed the power of the dimmer.
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On both sides of the housing are steel brush holders with springs in the form of a curled strip of steel. A spring is needed to hold the brush pressed against the armature collector even with strong vibrations and heating of the armature itself.
The spring presses the brush and as the brush erases, the spring falls lower and lower into the steel brush holder. Brushes are erased and reduced. When their length becomes insufficient, the angle grinder stops working. In expensive models, there is a spring inside the brush that pushes the brush away from the armature collector. In cheap models, brushes are not equipped with a built-in spring.
When choosing new brushes, it is better to contact the service centers of your manufacturer specifically for an angle grinder. The fact is that just as the graphic artist chooses twenty different simple pencils with different softness, the grinder manufacturers specially design brushes for a certain type of collector. If you use other brushes, for example, from a generator for a VAZ, then most likely the anchor will burn out soon, but for the first time, such brushes will fit.
The power button for the angle grinder is a plastic box with a mechanical linkage. The box is bulky enough to suggest that it commutes high switching currents and that the button goes not only to this equipment.
In the head of the angle grinder there is a gearbox that increases the speed disk rotation up to 11000 rpm The gearbox rod on which the disk is worn contains a sheared washer that sits firmly on the shaft and has a support pad with a rubber ring for seating the disk.
Nearby is a foot with cuts, which fixes the protective casing. For greater safety, the guard can be moved and locked. The foot is pressed down to the angle grinder and the flap is moved to the desired level, after which the foot is released and it fixes the flap.
Nuts for mounting the disc are self-locking SDS and ordinary with key holes.
The gearbox is supported by four screws. If you untwist them and carefully tucking the screwdriver open the cover, then the gearbox parts will appear. The gear on the armature shaft has a left-hand thread and is threadedly connected to the armature shaft.
The gearbox uses rolling bearings, i.E. Conventional bushings greased with grease. The teeth on the model with a power of 1100 W are straight, apparently this is quite enough for locksmithing, but in the 1500 W models, gears with curved teeth are used.
In order to remove the anchor, gently remove the brushes, remove the gearbox and pull the anchor out of the housing by the gear. At the other end of the anchor closest to the cord is a rolling bearing that is recessed into the housing plastic. To remove the anchor you need to pull hard and carefully.
An anchor is a steel rod on which a steel cage is assembled from plates. In the grooves of the cell, turns of copper insulated wire are laid. At the rear end of the armature, called the collector, all ends of the windings are brought out. At the front end of the anchor is a gear for transmitting rotation.
To win in the force that needs to be applied to the disk for work, use gear. For a 2 kW angle grinder, the anchor gear has 10 teeth and the circle gear has 41 teeth. It turns out that at a speed of rotation of the circle of 8000 rpm, the armature rotates 8000X41 / 10 = 32800 rpm. If we take into account that the number of collector contact plates is 36, then 32800X36 / 60 = 19680 Hz. This is approximately the frequency that interferes with the network and to eliminate which ferrite rings are needed.
The gear wheel is located on the shaft. In production, the gear was heated, and the shaft was cooled. After that, the gear was put on the shaft. The resulting connection is cheap, simple and does not practically make it impossible to remove the gear without damaging the gear case. Heating the assembled part will cause expansion of both the shaft and the gear. The only way to remove the gear is the puller. At the same time, the grippers of the puller paws must be thin and strong enough to enter the small gap between the housing and the gear.
The gear shaft is mounted on the thread. Probably, the manufacturers calculated that the gear of the anchor flies more often than the gear of the gearbox. On this model, helical gears to increase the power output.
The gear has a RIGHT thread. For spinning gear, you need to wrap it with a rag so as not to break the teeth when unscrewing, hold it with a gas wrench and turn it AGAINST THE CLOCK HAND.
After removing the gear, it becomes clear that the thread is not made over the entire height of the gear, but only in its small area. The section without thread allows you to put on the gear exactly, without distortions.
How to repair a do-it-yourself angle grinder
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Angle grinder does not turn on. The simplest DIY power tool repair
Many people are familiar with the situation when a favorite tool stops working for no apparent reason. And if the angle grinder does not turn on, then, often, the reason for this is a simple breakdown, which can be quickly eliminated without special knowledge and tools. Next, we consider simple methods for diagnosing and repairing a power tool using the angle grinder as an example. Initial state. The angle grinder does not start when the power button is pressed.
To do the work we need a multimeter with dialing function and a screwdriver. The first thing to check is the wire, or rather, the plug and the place where the wire enters the housing. Press the button and “massage” the suspicious areas. Most often, problems arise in the case. If this does not help and the angle grinder still doesn’t work, proceed to the next step.
We disassemble the case. To be sure, you can turn our tester into the dialer mode, and check the integrity of the wires from the plug to the entrance to the button.
Next in the electrical circuit is a button. Often, it is the malfunction of this unit that is the reason that the angle grinder does not start. In order to check this node, you need to put it in the ON position and “ring”, as shown in the following photo:
In this case, the button “rang”, which indicates its serviceability, so go ahead. In this angle grinder, a speed regulator is used, so it is also worth “ringing”, having previously set it to maximum power.
The next thing you should pay attention to if the angle grinder does not turn on is the brushes. In large angle grinders, brush holders are located outside, in our case, inside the case. We remove the brushes and inspect them. Make sure the integrity of the contacts on the brush itself. The main criterion for the efficiency of the brush is its degree of wear or size. In this angle grinder, it was their wear that became the reason for its failure. Therefore, replacing the brushes with an angle grinder will help eliminate the problem. For clarity, a comparison of new brushes and completely worn out.
If in your case all this turned out to be working, and the angle grinder does not work, then the last thing that can be checked without a special tool is an anchor. To begin with, we “ring” between the iron parts of the anchor and the collector lamellas. If it rings, it means that there is a breakdown of insulation and the anchor must be replaced.
Next, measure the resistance between adjacent lamellas on the collector. On all pairs it should be the same. If at any measuring point the resistance is several times higher, then we can talk about the breakage of the winding. It is worth noting that such a malfunction rarely leads to a complete stop of the engine.
If, after carrying out the above diagnostics, it was not possible to identify the malfunction and the angle grinder does not turn on, then it seems that you will have to contact the master.
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How to disassemble an angle grinder
Intensive operation of such a popular and demanded in everyday life angle grinder (“angle grinder”) necessarily leads to the need for its repair. But, most skilled people in such a situation rest on the question of how to disassemble the angle grinder, so as not to make much damage. Only knowledge of the device and the principles of disassembly, repair of the device allows you to independently carry out qualified repairs.
Constructive modifications of grinders
The angle grinder is very different in several design features:
- Power is the basis of all structural features: bearings used, type of transmission and hardness of metals used, build quality and materials used in the construction.
- Case features of the assembly. The transmission mechanism is necessarily located in a metal case, which, despite the general principles of assembly, can have various modifications. In most cases, the case of the mechanism has a cover with four tightening bolts or screws. It is worth considering that before disassembling the gearbox angle grinder, it is necessary to carefully visually examine the assembly joints of the body, showing the detail of the structure, i.E. What needs to be disassembled in advance.
- The quality of the materials used to assemble the angle grinder is very different from the manufacturer itself, so the celebrity and the availability of branded spare parts indicates the quality of the device itself and its maintainability.
Components Angle Grinder
To know, how to disassemble an angle grinder, it is necessary to clearly represent its design features, places and features of the connection of parts:
- The general case with a handle is usually made of plastic, has two halves connected by screws along the perimeter. Untwisting it allows you to get to the electric motor and all electrical components. Many models have a non-separable part of the housing in which the stator coils are mounted, and the entire device is disassembled by unscrewing the side “covers”.
- The electric motor angular grinder is fixed in the tides of the body. Pillows, and its recess reveals an unimpeded recess of the rotor from the stator. The engine bearings are also quite easily inserted into the body, but their landing on the shaft has a large interference, which very often becomes a problem in the situation of how to disassemble an angle grinder.
- The rotor is not a collapsible unit for self-repair, so you need to be careful with it so as not to damage the wires of the windings, the armature and geometric shapes of the metal components.
- The stator is an electric winding with a transformer steel housing. Independent repair of the unit angle grinder is not possible.
- The shank of the rotor with the gear teeth passes into the metal housing of the gearbox, in which the bearing can be reliably fixed, and its excavation without attachments with impact force can lead to cracking of aluminum.
- The problem of how to disassemble the reducer, an angle grinder, is found mainly in only one of its units. The fasteners of the driven gear on the output shaft and the extrusion of the unit from the removable housing cover.
DIY gearbox disassembly
- In most cases, access to the transmission of the gearbox can be performed without a general disassembly of the angle grinder, and you just need to unscrew the gearbox cover, which is fastened with four or six screws, depending on the power of the device.
- Before disassembling the gearbox, the angle grinder must be unlocked with screws and the protective cover of the cutting wheel removed.
- Having unscrewed the bolts of the gearbox cover, it is removed together with the output shaft and the driven bevel gear, and the “view” of the assembly structure and the mechanism development is “opened”: in cheaper models non-ferrous metal bearings (brass, bronze) are installed, the replacement of which is very problematic from.For tight fit in an aluminum case.
- Installing new bearings on the shaft does not pose any special problems, as it is quite easy to install in place by crimping due to an additional suitable spacer. Dismantling the old bearing from the shaft is advisable to carry out its “destruction”, for which both clips are carefully cut with a file or a cutting wheel of a grinding and milling machine.
- The bevel gear can be cast with the output shaft or removable. Dismantling the assembly is an extremely rare occurrence, as the node is sold in pairs. But gently squeezing it out of the case without a puller is not an easy task, because you can use a careless movement to crack a metal case. Disassembly can be facilitated by heating in an oil bath or, in extreme cases, in boiling water, while it is unacceptable to perform heating with an open flame to disassemble the angle grinder gearbox.