How to disassemble the gear reducer of a Makita angle grinder. How to remove the anchor from the angle grinder?

Table of Contents:

disassemble, gear, reducer, makita, angle, grinder

How to disassemble the angle grinder yourself

In all the time I have been using the power tool, this is the first time I have “burned” it myself. During prolonged use, my Makita 9555HN angle grinder started to smoke very badly. It was caused by haste and inattention at the same time. In the combination of all my actions and events there was a very strong overheating of the tool. Timely overheating was not noticed due to the fact that the work was done in welding boots. Since they are leather, they are safer to work in, as they will not wind up unlike rag or knit ones. And, since the mittens are designed to protect against temperature, the work was carried out as if nothing had happened.

In addition to just working for a long time, which lasted about an hour and a half, there was another aggravating factor, the tool used some heavy tooling in the form of a thick, six-millimeter grinding wheel and a metal brush in the form of a cup.

The operating time of this copy of the angle grinder is small, so we will repair it.

Disassembling the tool. The process is simple enough: unscrew the screw that secures the black plastic cover and take it away through the power cable. Next, we lift the spring-loaded locks of brushes and remove the brushes (there are two, located on different sides).

We proceed to the disassembly of the front of the angle grinder. Loosen the four screws that fasten the reducer and take it off. Further, it is necessary to take out a rotor of the electric motor. For this purpose it is necessary to use a screwdriver. Fit it into the technological groove and turn it carefully, checking the process. The rotor is easy to pull out, without any excessive force (the main thing is not to forget to remove the brushes before).

We blow the rotor with compressed air and examine it. Externally there is absolutely nothing to complain about. it is perfect. The enamel on the visible part of the wires is not darkened and retains its integrity. Unfortunately, there is no way to check it for intercircuit closing. Put it aside and continue dismantling.

Now we need to get to the stator. After removing the rotor, we’ve got access to the fasteners for the plastic stator protection. Unscrew the two long screws and take it out. Before you start to remove the stator you should disconnect its winding and straighten out the wires. To remove the stator you can use a rubber mallet. The process is as follows: hit the front end of the housing with a hammer lightly, and because of the rather large mass, the stator will start to come out of its seat. When removing the stator it is necessary to make sure that the wires go through the technological windows freely and do not catch on anything.

Inspection of the stator revealed burnt out winding conductors. The enamel on them is significantly darkened and damaged. The stator needs to be replaced.

We still have an open question about the rotor. I recall that in some large retail outlets that sell parts for power tools, they can tell you and check some parts. Take the stator and the rotor and go in search of parts.

But we have to take the rotor apart a bit before we go to the store. We need to remove the plate and bearing from the front. In the opposite case it may be difficult to check it. To remove the plate you need to unscrew the nut M6. The bevel helical pinion is mounted without a key, the fit is loose. Having removed the pinion carefully pull off the bearing together with the plate.

As expected, it was not difficult to check and purchase the necessary parts for replacement. All we had to do was to get to the right specialty store for those very parts. Here we checked the rotor, which in its turn is also “melted”, and bought new parts.

Assembly begins with the preparation of all parts and components of the angle grinder. First you need to blow out the dusty elements with compressed air. Then we washed gear parts in gasoline. After that, let’s lay out all the components of the angle grinder and proceed to assembly.

It can be assembled without any effort and without using any special tools. A simple hand effort is enough. The main thing in this process is to correctly guide the four wires that are connected to the terminals. You should also pay attention to the red wire. jumper (the one that connects the two windings). When installing the stator this wire tends to take the position right in front of the fixing hole of the plastic shield. If you do not take it into account, then in the process of further assembly, when you screw in one of the screws, it is guaranteed that the wire will be broken.

Once the stator is in place, install its shield.

Next, it is necessary to prepare the new rotor for installation.

Here you need to install the previously removed plate, bearing, pinion and nut, and do not forget to replace, from the old rotor from the rear bearing, the rubber ring. It is marked under number 3 in the diagram, and is called a labyrinth rubber ring.

After completing the above-mentioned work, put the assembled rotor in place. Then, using four screws, screw the gear housing. Tighten the screws evenly crosswise.

The rotor is now locked in place and the brushes can be installed. We place them in the special channels brush holders, fix and connect the flexible contacts.

How to remove/remove the needle bearing in the angle grinder

It is no problem to press in a new needle bearing, but to remove it you need to use the original puller. The following video shows the author how to make this device and what it does in practice.

The extractor is a collet with collars on the ends of the moving blades. The collet is machined on a lathe and the center hole is drilled for the expander pins. The puller is inserted inside the bearing and the flanges, following the movement of the rod through the bore, rise up and rest against the shoulder of the ring. It is possible to extract the bearing from the housing with the help of levers made of rebar with ground edges, which are not very impressive looking, but reliable, resting on an inserted washer.

Important: A needle bearing has a much longer service life than a plain bearing. However, the spindle shaft wears out during operation and must also be replaced. In the video described, the author found the replacement option. However, in most cases, it can create additional problems.

How to independently perform repair of angle grinder

One of the most common household appliances for repair and construction work is considered an angle grinder, or angle grinder (angle grinder). When operating the machine, it is not uncommon to see strong loads and careless handling, which leads to wear of parts and breakage. But it is possible to repair the angle grinder yourself. To do this, it is worth looking at how to do the repair of angle grinder with their own hands on video.

  • The angle grinder anchor (rotor) is the most overloaded element of the angle grinder mechanism. It is exposed to temperature, electromagnetic and mechanical damage, so its failure is not surprising. Armature windings tend to burn out when heated, resulting in short circuits. Therefore, the repair of the angle grinder armature with their own hands. a frequent practice.
  • If the collector fails during operation due to strong vibration of the brushes, they are burned, so there is a very noticeable sparking. Brushes carry current to the collector.
  • Subject to heavy wear and bearings on the rotor shaft, which can, if not replaced in time, completely destroy. They must be checked in the case of extraneous noise from the machine.
  • The fixed part of the angle grinder motor is the stator, which contains the winding. The stator itself is seldom the cause of angle grinder failure.
  • The gearbox is a power transmission mechanism that requires timely cleaning and lubrication.
  • The easiest way to replace the brushes on the angle grinder, but this is the most frequent procedure in the repair, t.к. they are made with graphite.

Recommendations before you repair

It is worth bearing in mind that the technology of repair angle grinder different models and manufacturers may differ. So, the repair of the Interskol angle grinder with their own hands is different from the repair of faults of the Bosch grinder.

That is, it is important to know the features of your angle grinder and have on hand the scheme from it, then the repair of the angle grinder with their own hands is possible to perform easily and efficiently.

Repair of angle grinder with their own hands

Only after getting acquainted with the detailed description and diagram of the angle grinder, you can proceed to its disassembly. Repair should have a certain sequence of actions. And the most important thing. the observance of safety.

See also  Attaching a Cutting Wheel to an Angle Grinder

Power cord

Break of electrical wire at the handle. the most common problem of failure of the device to work. To verify this fault on the button, you need to use a standard voltage tester. Only after that should you check whether the button itself still works.

Bearing replacement

If you notice an increase in play on the spindle shaft, then the needle bearing needs to be replaced. By the way, it is not in all models of angle grinder. To disassemble it, disassemble the housing and take out the large pinion shaft.

Using a machine tap, take out the inner ring, which is in the damaged bearing.

The tap must be clamped into the chuck of the electric screwdriver and screwed into the bearing rim. When the bottom of the housing has been reached, continue to screw in slowly so that the cage rises along the thread.

Disassembling the helical gears

Damage to the helical gears causes the reducer to break. Often the small drive gear attached to the rotor shaft is replaced, which is attached in two ways:

The driven large pinion can also be attached by means of a keyed joint, but also by pressing it onto the shaft.

Differences in repair angle grinder Interskol

If the correct operating conditions are observed, the Interskol angle grinder repair with your own hands can be made very rarely.

To replace the gears, disassemble the gear housing, and release the cover. Since the idler is attached by pressing, it must be removed with a press. Then remove the bearing with a puller.

If the stator is burned out, you need to calculate how many turns of wire, and what is its cross section.

It is not superfluous to see the Interskol angle grinder repair with their own hands on the video.

Peculiarities of repair of Bosch angle grinder

The design of all models of the Bosch line has an identical circuit. Repair of Bosch angle grinder with your own hands is usually reduced to the replacement of bearings.

The spindle shaft is pressed on the idler pinion. Held on a needle bearing in the gear housing, which, when worn, leaves only the cage inside. The driving gear is attached to the rotor shaft with a left-hand thread, and then fixed with a nut.

Makita angle grinder repair

The Makita angle grinder is distinguished by its protective casing, which can be quickly removed. This can be called a plus, t.к. Angle grinders of this company are most often subject to breakdowns. This applies mainly to counterfeit products, flooding the domestic market.

Real angle grinder firm Makita is famous for its durability and reliability. Regardless of whether a fake or real angle grinder fell into your hands, the most common cause of failure will still be the gearbox and its gears.

This is noticeable in case of slipping of the idler pinion, gear jamming and shaft play.

When repairing, the angle grinder must first be disassembled. Disconnect the gearbox from the stator housing by loosening the brushes and unscrewing the screws. Next, the screws holding the rotor cover are removed.

The idler pinion can be removed with a press, and the drive pinion is keyed with a locking nut. The rotor shaft bearings can be removed with a puller.

Thus, no matter what angle grinder you have, with proper study of the problem you can repair the main faults with your own hands. The main thing is to correctly understand the scheme and have the necessary tools for repair.

Despite this, the angle grinder is a complex mechanical power tool, and not uncommon cases of damage to the more difficult-to-reach nodes of the mechanism. In this case, if you have not encountered this type of failure before, it is more efficient to consult specialists about your problem first.

How to Disassemble the Gearbox of Angle grinder

The process of angle grinder disassembly is inextricably linked with the angle grinder gearbox disassembly, as they form a single. Angle grinder has the option of disassembling not without the need to disassemble the gearbox, but here such disassembly will not

Servicing Makita GA five thousand thirty \ Fixing Makita five thousand thirty \ Repair of power tools \ maintenance tool

And you, shared the vid??)))) My affiliate program on You Tube:.

Angle grinder repair: the main types of malfunctions

Over time, all types of power tools can fail. Often these breakdowns are caused by improper operation or poor quality tool components.

One such tool is an angle grinder or angle grinder. If the tool does not work, then do not immediately buy a new one, because such products can be repaired.

To repair an angle grinder you need to know its design as well as its principle of operation.

How an angle grinder works

Repair of the angle grinder with their own hands begins with the fact that you should find the cause of the malfunction. To do this, you need to find out the principle of operation and design of the tool.

The principle of operation of the device is based on the conversion of electrical energy into mechanical.

The mechanical energy is the rotary motion that drives the tool shaft with the corresponding bits.

This means that the angle grinder consists of two parts: electrical and mechanical. Breakdown can happen in any node, so it is important to know the structural elements of both parts. The main elements of the angle grinder include:

  • Plastic housing.
  • Two-phase electric motor.
  • Gearbox.
  • Power button.
  • The sleeve bearings.
  • Brush unit.
  • Power cord.
  • Speed regulator (for some models).

The housing is made of impact-resistant plastic. The design of the housing combines an electrical circuit with mechanics. The motor rotor rotates through the supply of electrical current. Plain bearings ensure the rotary motion of the rotor shaft. The shaft is fitted with a toroidal gear at its end.

It drives a flat gear, which is located in relation to the shaft at an angle of 90 degrees. This is how the angle grinder works. In addition to the two plain bearings on which the rotor shaft rotates, there is another bearing unit in the angle grinder.

It is located on the working shaft of the mechanical part of the tool.

Typical malfunctions of angle grinders and methods of diagnosis and repair

Repair of angle grinder with their own hands begins with determining the cause of failure. If it is not possible to determine the cause, the method of elimination of failures from the simple to the complex. For self-repair it is necessary to identify initially, where is the breakage. in the electrical or mechanical parts.

  • Gearbox malfunction. The helical gear is attached to the rotor shaft, so if the motor works, but there is no rotational motion of the working part, the reason lies in the gear mechanism. In order to see what is wrong with the gears, it is enough to disassemble the tool body. The cause of gear failure is most often a slipping of the teeth of the large pinion of the shank. The reasons for this are varied:
  • Lack of lubricant;
  • High loads on the tool;
  • Poor quality of components;
  • improper operation.

Either way, once a malfunction has been detected, it must be corrected immediately. This can be done by replacing the faulty pinion. Most often, you can find them on sale in a pair with a helical gear, which is installed on the shaft. It is recommended to replace two gears in a pair, after which they should be thoroughly lubricated with a special lubricant.

These are the basic types of problems with the mechanical part of the tool that you can easily fix. Now let’s focus on the more complex part. this is the electrical. In the electrical part, these types of breakdowns can occur:

  • Damage to the mains cable. If the mains cable is damaged, the voltage to the power tool stops, so the angle grinder will not function. The cable can be damaged for various reasons (crushed, crossed, cut), but it is not difficult to determine the breakage. It will be necessary to use a tester, which is carried out wire-checking. In this case, it will be necessary to disassemble the tool.
  • Failure of the control button. angle grinders can be designed with an ordinary button to start the tool or with a soft start. In a normal button, most often the contacts are oxidized or clogged, which is enough to clean with an emery. In buttons with speed regulation the cause is often hidden in the damaged contact plates. The tool can be disassembled and then its integrity checked. If a damaged contact plate is found then the starter unit needs to be replaced.
  • There is a problem with the brush mechanism. Brushes are consumables and have a long service life. If the tool is many years old it is well worth taking it apart and having a look at the brushes. If they are worn out, they need to be replaced, which is not very difficult to do at all. If the brushes are still long enough, then the cause may be in the collector mechanism, which shows obvious signs of oxidation or contamination. It should be cleaned and the condition of the tool checked afterwards.
  • Rotor and stator malfunction. The stator or rotor winding can be burned out if the tool is operated under high loads. You can determine the problem with a multimeter in resistance mode. The best option is to take the engine complete to a repair shop, where the cause of the breakdown will be identified and corrected. Usually a burned-out winding is rewound, but it all depends on the extent of the fault.

Prevention and maintenance

To avoid repair of the angle grinder, you should periodically carry out its diagnostics. First of all, it is important to take care of the mechanical part, which suffers from a lack of lubrication and the occurrence of dust and moisture. There are special greases for angle grinder, both domestic and foreign-made. Grease the gears and bearings differently.

The basic recommendations for extending the life of an angle grinder are as follows:

  • Regularly perform maintenance of the tool.
  • Respect the standards of operation and storage.
  • Exclude prolonged loads, especially for domestic models.
  • Replace worn parts in good time.

Collector motor diagram with directional switch

So, we open the device and see a pile of dust and dirt that accumulated over a long period of operation, we clean it all and wash with wipes and degreaser.

See also  Disc On Angle Grinder To Remove Rust

Check the brushes, and all the electrical connections on the terminals by crimping and cleaning, take out the rotor collector motor and check it visually inspection of the winding and plates, that nothing would stick, the bearings should be intact without cracks, and they should rotate freely without jams, noises and backlashes.

Then we proceed to the switch, it turned out, and it became the culprit, here the button switch commutes two conductors of the circuit at once. The drive lever itself was purged with silicone grease, so it can move easily in its groove guides to the switch.

The switch can be removed and disassembled, I could not repair the burned out half, so I shorted one of the wires directly, and now the second serves for switching on and off.

The contact has come loose in the switch, it began to spark and heat, and part of it melted.

How to change the shapting of angle grinder

It is of course possible to replace the entire switch, which would be right, but the owner wanted the cheapest possible, since the tool is not very expensive, and no longer new, so I had to do this, a new switch is in the city of about 400-500, which is not very cheap.

disassemble, gear, reducer, makita, angle, grinder

After assembling the angle grinder, be sure to test and check the idle mode before you give it to the owner.

So, briefly describe what’s what and why. I like the angle grinder very much, proven over the years. There is a little bit of it, which I rate as absolutely insignificant. One of its greatest advantages. a very reliable gearbox, gears and housing in general, a powerful motor, convenient size. My last one, which I still have, burnt out after two years of abuse. The rotor on that grinder I did not change, I decided just to buy a new one, because I doubted the quality of spare parts, was afraid that they can send a fake one for the original, or in general the quality is not right. But with the new one had an accident, apparently some kind of metal scale got inside the anchor channel and closed it. I poked around, found an interesting, credible option, and ordered paired with two sets of custom brushes, which are also pretty decent looking, and inspire confidence. ) In general, all this, I wanted to do with the old, while alive new, but who knew. In general, here’s a video, there’s a comparison and description of the repair process with tips what’s up. I hope you like it. )

Later, in an hour or two, I’ll make a short video with the results, so to speak. )

Question, am I the only one with such lags in Movavi?? I think to soap it.

For one thing, here’s a link where you bought, with my part, no complaints and claims, checked himself, all satisfied. rotorua.com.ua/product/jalgarki-interskol-125-900/

How to Remove the Gear Gear of an Angle Grinder

Disassembly of angle grinder does not require special locksmith skills, it does not cause serious difficulties. However, the work must be done very carefully, not with the utmost care. Like. (You can read about it on the internet. Some sites show videos with detailed workflow. Dismantle the angle grinder is necessary, not only when the oil is out of service does not need to replace any part, it must be done to clean the tool of dirt.

, The first thing to do is to disassemble it and clean it well, in the bulk of the tool begins to work.

For this reason, the actions that are needed to disassemble the angle grinder, must know who owns such a tool does not want it to work for a long time not quality. In stores there is a large assortment of this mechanism, made by ambiguous companies. They differ:

However, the models of any manufacturer have the same technological assembly. Our client is left with

Angle grinder are equipped with the same set of parts.

Main modules used

  • The body, usually made of special shockproof plastic.
  • Powerful electric motor.
  • Quality reducer.
  • .
  • Motor switch.
  • SJS system. The presence of an accounting system provides the tool to work smoothly without surges. Already today, similar oil turns off the angle grinder if the passage of the disk jamming, reduces vibration as much as possible. How oil saves the operator from serious injury.
  • Protective guard.
  • An extra handle. It holds the angle grinder in place while you work. The handle can be set in various positions, which makes the tool extremely versatile.

READ Interskol Electric Screwdriver Gear Repair Da-18er (1 part)

What you might need for the job

The process of disassembly of the angle grinder requires several tools:

Difficulty due to the fact that the parts have a very tight contact. This allows you to cope with the highest loads. No shifting or oscillating motion of parts during operation. This, the disassembly will make much more reliable master, but of course try to yourself with maximum accuracy.

Tools needed for : round pliers, ruler, caliper, pliers, power drill, steel brush, megohmmeter.

How to change the gears on an ordinary angle grinder \ Angle grinder Energomash \ Repair power tools \ M Brest

While starting to disassemble the angle grinder, it is necessary to prepare the place of work, removing from the workbench our unnecessary parts. A clean table makes it possible not to accidentally lose any small part.

First unscrew the bolt holding the hood. Remove

it is very easy, there are no tight connections. Then you need to unscrew the screw, remove the plastic plate. The outer hood must be slid toward the cord.

For the most part, our customer remains a model of lathes have a variety of devices. However, the common part is the electric motor, which includes:

An additional mandatory part of the angle grinder is the gearbox, designed to regulate the power not speed. The electric motor, along with the gearbox, is mounted in the housing.

Gearbox of attachment

It is held by four screws. They must be unscrewed not with extreme care remove the gearbox from the angle grinder housing. Disassembly is necessary to clean the gearbox, not to replace worn parts. This is one of the most important nodes of the angle grinder, which experiences tremendous stresses in its operating time

READ The angle grinder buzzes but doesn’t rotate

To remove the rotor from the gearbox housing, it is necessary to. that holds the rotor. Pull out the rotor with a special puller. This operation is connected with some difficulties, if you do not have special skills, it is better to leave such work to professionals. You can’t do without a puller.

It is necessary to note, that for simple removal of dirt, such detailed disassembly is not necessary. As oil is needed only for replacement of worn bearing as it is also called worn rotor.

To remove the armature, you must first remove the brushes from the gearbox, then gently pull the armature out by holding the gear.

This operation requires some effort. Removal of the armature from the housing must be done very carefully, as they break easily.

When in your own observed a strong spark, a large heating of the housing, you just need to take out the armature to clean the collector. The machine is now ready for use again.

How to Disassemble a Gearbox: Advice

When the gearbox completely refuses to work, it requires a complete disassembly to replace parts not thoroughly clean. To do the work, it is necessary to prepare a locksmith’s vise. The work is performed in a specific technological sequence:

  • Use a wrench to loosen the bolt holding the gearbox housing.
  • The rotor body is fixed with great care in a vise.
  • Extract the body by soft blows with a hammer.
  • Find a suitable position for the rotor to remove the bearing. Clamp the vise again.

READ How to Cut a Tile with an Angle grinder without chipping

Putting a block of wood to knock out the bearing. To remove the pinion

Grinder Repair – How to Replace the Gear Bearing

  • Wrap a rag around the rotor and do not clamp it with the jaws of the vise.
  • The pinion is also wrapped in cloths and turned counterclockwise using a gas wrench.

How to remove the spindle: tips

The spindle axle works in conjunction with the main gear, which contains:

To disassemble the spindle housing, it is first necessary to remove the main pinion, why special tools are used.

, place the housing in a vice. Using a wooden block and hitting it with a hammer, with great care remove the spindle, where the bearing is. Removal of the bearing is done in the way described above.

Disassembly of the gearbox should be performed regularly, especially when the tool has been subjected to intensive use. After disassembly, grease is replaced. Lithol-24″ is used. It should be noted that the lubricant must be changed continuously at regular intervals. This helps to increase lifetime of the gearbox

Repair of the angle grinder gearbox with their own hands

To make the repair of the gearbox of the angle grinder with your own hands, in principle, is not difficult. There remains one big, but will such repairs be profitable? The proposed repair methods do restore the functionality of the tool, but do not eliminate the cause of the malfunction. е. The same failure will happen after a while.

Unlike other proposed materials, on the subject of repair of the gearbox of angle grinder, in this article you will find not only a description of the repair, but also ways to eliminate the occurrence of similar failure in the future, of course, when it is possible in principle.

Typical gearbox failures of angle grinder

In contrast to the breakdown of the electric motor causes of failure of the mechanical part of the power tool, in particular, the angle grinder is not so much. There are five of these.

  • Wear or total destruction of bearings.
  • No clutch of the gears.
  • Gearbox jamming.
  • Insufficient grip of the gears manifested by the load.
  • Increased backlash of the shaft due to mismatch of the housing and bearing diameters.

Angle grinder gearbox repair

As already mentioned, the repair of the gearbox of an angle grinder itself, if you have the right tool, is not so difficult. Basically it comes down to finding the right parts. The peculiarity of quality repair is that you want not only to eliminate the malfunction and replace the part, but also to find and fix the cause of its occurrence.

How to replace bearings

About replacement of bearings is easier to say, more difficult to do. It is good if there are suitable pullers, then there will be no problems with the pressing of bearings, but if there are no pullers, then as always, the hammer and some suitable tools for this operation will help.

See also  How to Cut an Angle Grinder Under 45 Degrees

If you plan to do power tool repair more or less regularly, even if by necessity, it is worth thinking about buying two types of pullers from the shaft and bore. You can buy them on the same AliExpress, thank God the price is small 5. 20 for each. You can also buy the necessary bearings there, they cost about 1.5.

Causes of gearbox jamming

The cause of jamming may be the destruction of one of the mechanism parts. If one of the gearbox parts fails during the operation, the further scenario is unpredictable.

You’re lucky if it’s limited to no clutch at all.

The gearbox can also wedge, and parts of the destroyed parts will jam the driving mechanism, and then the consequences can be much worse, up to the question of whether further repair is advisable.

disassemble, gear, reducer, makita, angle, grinder

Slipping of gears

I will describe and fix this fault in more detail, because its elimination will help to avoid other failures.

There is always a temptation not to buy new gears, but to use the old ones, even if they are a bit worn, but they are not worn out at all. Unfortunately, nothing good can come out of this endeavor. You’re wasting your time and energy. Once the flattened gear-edges can not be restored, they will in any case slip.

If the process of teeth wear has gone too far, the angle grinder produces a characteristic whistling sound when it is switched on. Gears will need to be replaced in pairs. You can visually judge how worn out the teeth are.

On one side of the teeth of both gears a characteristic radius is formed which gradually turns into a chamfer formed by the slippage of the mating gears.

Why does this malfunction occur?

  • In my opinion, the main reason lies in the inaccuracy of design calculations of gearbox dimensions, everything is done on the spot. Then, further on, the lack of technological discipline and, as a consequence, defects or short life of the tool.
  • Another reason, inconsistency of materials. If someone was involved in the repair of Chinese products, he knows what I’m talking about.
  • Loosening the fastening of the gearbox cover. The cause of this malfunction is more likely carelessness of the user, the power tool should be watched, but it may turn out that in one of the cover fasteners to the body elementary torn threads.

How to fix this problem

Of course, the gears will have to be replaced in any case, but the tool performance after repair will not last long. You need to eliminate the cause of the problem.

There are four ways to repair angle grinder suffering from insufficient clutch of drive and idler gears.

  • Grind down about 1 mm of the metal surface of the gearbox housing adjacent to the cover or grind half of it on the housing and the other half on the cover. This method seems to be the easiest of all proposed ones at first sight. In fact, without flat grinder it is hardly feasible, at more or less quality level. over, grinding the housing will reduce the depth of the blind holes for the mounting screws, and this can affect the proper seating of the cover to the gearbox housing.
  • Shift the pinion (small) pinion closer to the idler pinion with a shim washer. In principle, this method is as good as the next two, but the problem here is calculating the size by which the pinion should be shifted. Insufficient convergence will do nothing and too close contact will only speed up the wear process.
  • Set the idler pinion on the shaft from the cap bearing closer to the idler pinion, about 1 mm. The idea is simple, a retaining ring prevents a tighter fit, which in turn is held in a retaining groove machined into the shaft. Therefore, it is necessary to mill a new groove, just below the native, about a millimeter, and under the driven gear put a washer, the thickness of which is equal to the distance by which the locking groove is shifted.
  • Set the height of the shaft itself, with the idler sitting on it. To do this you need to mill the bearing faceplate on the shaft. In this case the shaft is slightly displaced towards the cover (in my case by 1.3 mm). Together with it the idler gear will also shift.

Turning the shaft is probably the easiest and most effective solution to the problem of insufficient gear coupling, of course, when you have a lathe at hand.

Drilling machine from the engine from the washing machine and the gearbox from the angle grinder

Materials and tools used by the creator:

The list of materials:- Motor from washing machine 650W /1350 RPM;- Gearbox from 180th angle grinder;- Angle;- Round pipes;- Sheet steel;- Bolts and nuts;- Spring;- Switch;- Cable with good insulation.

The manufacturing process of the drilling machine:

Step 1. Gearbox modificationFor the machine it comes in handy gearbox

The 180° angle grinder, it lowers the rotational speed of the motor more than the speed of the lawn grindergearbox from 125 angle grinder, as a consequence, we get the highest torque, and the axis of the gearbox is thicker. The creator, using an angle grinder, cuts off a piece of the anchor and knocks out the rest of the anchor from the axis. Also cut off a piece of angle grinder body to screw this part with bearing seat to the gearbox. If you do not have it, you can weld it yourself from sheet steel, using a piece of pipe as a block.

Step 3. Make the base for the drilling machine, it must be very strong, so that the whole structure will not fall off. You can use a piece of a suitable channel as a base. If you don’t have a channel, you can weld it from thick steel. To attach the machine to the base, we weld the ears to the base with bolts.

Also weld to the base 4 racks, it can be pipes or iron bars. At first, the rods are inserted into the carriage, and later tacked to the base. This is the only way to install the rack correctly.

Step seven. Finishing touches and testsInsert the gear shaft drilling chuck, to screw the chuck, you can weld a nut to it for the angle grinder or cut the thread directly in the chuck.

Paint the frame so it does not rust, now the machine looks great. Put a useful circuit breaker for sharp turns off the machine if anything. The machine is ready, the creator has put in a chuck a huge drill bit and drills his monster all in order, from timber beams, and ending with a thick sheet steel.

The machine showed itself perfectly, a machine for a real man. At this point the project is complete, I hope for you, homemade attracted, and you found yourself a useful idea. Good luck and inspiration if you decide to do it again. Do not forget to share with us your thoughts and self-made!

Receive a selection of new self-made machines in your inbox. No garbage, only useful ideas!

Filling out the form you agree to the processing of individual data

Angle grinder repair with your own hands. troubleshooting typical malfunctions

The main principle in the repair of any electrical equipment is the postulate “move from simple to complex”.

Whether it’s a domestic electric cartridge or a turbine at a hydroelectric power plant. the repair sequence should rule out elementary malfunctions in the first place. Electrics and electronics are not called the “two sciences of contacts” for nothing. Typical malfunctions of bolt cutters, along with techniques for fixing them, are as follows:

  • An instrument suddenly stops showing signs of life. With 90% probability we can conclude that the current from the socket does not reach the electric brushes. That is, the problem is either in the power plug, or in the wire itself, or in the mechanism of the “Start” button. It is enough to disassemble the case and “test” the cable with an ordinary tester for breaks. very often it is enough to replace the wire, and the angle grinder will work like new;
  • The wire and plug are secure and the tool is still immobilized? It is necessary to disassemble the starting mechanism, and it is desirable to mark the removed contacts. if you later connect them incorrectly, it could burn out the winding or jam the armature. The start button can be replaced by any similar, working parameters are marked on it quite legibly;
  • The “Start” button and the power wire are in working order, but the angle grinder does not want to work? It’s time to take care of the reel holders. Very often it is enough to clean the contact plates on the collector, and there is a long-awaited spark and a steady hum of the mechanism. If not, it is necessary to replace the brushes. The service life of these devices is usually limited to several years. Some models of grinders are available with soldered connection of electric brushes, it is necessary to unsolder and put new ones in a set, their partial replacement is not allowed;
  • After replacing, carefully inspect the old electric brushes. if they have uneven wear, this is a clear sign that the center of gravity of the tool or its moving interior. It is better to contact a specialized firm for repair of complex electrical equipment. independently adjust the balance without experience is unlikely to succeed.

Brush replacement refers to the “top of the first level” in self-troubleshooting in electric grinders. You can and further describe repair recommendations, how to disassemble the gearbox of angle grinder, to rewind its winding or reconfigure the electronic stuffing. But serious breakdowns require a serious approach to work. If you have never seen this gearbox, how can you repair it?? The chance of turning on an angle grinder depends on your common sense. saving on a professional repair will cost you the entire tool.