How to repair the stopper on an angle grinder

How to repair the stopper on an angle grinder

Over several decades, the external parameters of the angle grinder have not changed much, with the exception of improved models, which use a battery as a power cell. The basis of the tool is a housing with built-in asynchronous motor and gearbox, and screwed to the handle with a protective casing.

The power tool can be used with cutting and deburring discs, and there are also sanding discs. Like all tools, the grinder can refuse to work, but more often than not it is not so difficult to troubleshoot. This may require disassembly of the body and minor repairs. However, it is necessary to understand the device of the angle grinder, in the scheme of which there are the following elements:

The functionality of all the components is essential for the correct operation of the system. When any part fails, the grinder becomes a useless tool. In order for the angle grinder disc to rotate, the armature must rotate and drive the gearbox, and the faster the armature rotates, the greater will be the speed of the disc. The commutator is a kind of pad to which the contacts of the power and controlling electric components lead. The collector receives the voltage from the brushes and the electrical energy is then converted into mechanical energy.

The polished brushes pad can be seen when taking the housing apart. The power cable feeds current to the brushes, which transmit the voltage to the collector. Most of the time the brushes give off a glow, and depending on the glow you can determine whether the brushes or the armature are working properly. Equally important is the gearbox. The main task of the reducer is to transmit motion from the armature to the drive shaft, on which the disk or other attachment is mounted. The power of the power tool depends on the design of the gearbox, since it is determined by the number of teeth on the main gear wheel.

The stator is considered to be a very complex technical component in the electrical circuit diagram of the angle grinder. There is a winding in the stator that determines the rotation of the rotor. If the winding fails, its rewinding is rarely performed independently and even more rarely can be successful. At such malfunctions it is not worth the risk. for troubleshooting it is necessary to contact an experienced specialist.

Electrical configuration of the angle grinder

Over several decades, the external parameters of the angle grinder have not changed much, with the exception of improved models, which use a battery as a power element. The base of the tool is a housing with a built-in asynchronous motor and gearbox, and a handle with a protective housing is bolted on.

The power tool can be used with cutting and deburring discs and there are also discs with sanding flap blades. Like all tools, the grinder can refuse to work, but in most cases it is not too difficult to troubleshoot. This may require disassembly of the housing and minor repairs. However, it is necessary to understand the construction of the angle grinder, in the circuit diagram of which there are the following elements:

The functionality of all elements is very important for the proper functioning of the entire system. If any part fails, the grinder becomes a useless tool. In order for the angle grinder disc to rotate, the armature must rotate and drive the gearbox, and the faster the armature rotates, the greater will be the disc rotation speed. The manifold is a peculiar part in the form of a platform, to which the contacts of the power and controlling electric components lead. Collector accepts voltage from the brushes, and in the subsequent process, electrical energy is converted into mechanical energy.

The brushed pad can be seen when the housing is disassembled. Through the power cable, the current flows to the brushes, which transmit the voltage to the collector. Most often the brushes give a glow, and depending on the glow you can determine whether the brushes or the armature are working properly. Equally important part is the gearbox. The main task of the gearbox is to transfer motion from the armature to the work shaft, on which the disc or other device is mounted. The power of the power tool depends on the design of the reducer, because this parameter is determined by the number of teeth of the main gear of the reducer.

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A very complex technical node of the electrical circuit diagram of the angle grinder is the stator. There is a winding in the stator, which determines the rotation of the rotor. If the winding fails, it can rarely be rewound on its own, and even more rarely can it be successfully rewound. When such malfunctions do not take the risk. for troubleshooting it is necessary to contact an experienced professional.

Startup diagram

The angle grinder is designed to convert electrical current into mechanical current. The interaction of all components of the angle grinder is shown in the wiring diagram of its electric drive.

  • After the power cord is plugged in and the start-up is turned on, electric current is applied to one of the brushes.
  • After passing through the collector winding, the current appears on the other brush that energizes the stationary windings of the stator.
  • Magnetic fields created by stator and rotor windings interact with each other, causing rotation of the rotor fixed in the bearings. Together with it, the torque arises on the bevel gear planted on the armature. The other bevel gear, working in tandem with the first, rotates the spindle with the angle grinder’s working tool.
  • Additional outlets for stator or rotor windings make it possible to increase the functionality of the power tool by creating different control systems.
  • Collector plate contacts send rotor speed signals to a tachogenerator or hall sensor. They are used to maintain the necessary speed of the angle grinder.
  • To protect the angle grinder from overheating, there is a thermal protection unit. It shuts off the tool if the sensor indicates the maximum allowable temperature of the angle grinder’s test surface.

Understanding the role of each of the components that make up the angle grinder’s electrical circuitry allows you to correctly determine the cause of the grinder’s failure. If the cord, button, and brushes are in good condition, look at the condition of the drive.

Angle grinder gearbox repair. mastering applied mechanics

Remember when you unscrewed the 4 screws on the gearbox? You won’t find anything special underneath, just a sea of grease, rolling bearings and gears. In models with power up to 1100 W are usually used spur gears mounted on the armature, but angle grinders with higher power, such as 1500 W, require helical spur gears. Both have a conical shape, since the axis of the reducer rod intersects with the armature shaft, and transmission is possible only by angular meshing of the teeth.

Gearbox controls the speed of the blade thanks to the number of teeth on the sprocket. For example, if the armature gear wheel has 10 teeth, and the gearwheel has 41, then, if the anchor speed is 32800 rpm, the drive will give only 8000 rpm for the same time. As a rule, the repair of the gearbox of an angle grinder is only to replace the gears. If the disc gear breaks, it will be very difficult to remove it for replacement, in the gearbox this node is the best fixed.

However, if you have among your tools a universal puller with sufficiently thin legs, there should be no problem. With the gear of the anchor shaft should turn out even easier, it is always kept on the right thread, but do not hurry to unscrew, first wrap a rag, so as not to damage the teeth with an adjustable wrench. And do not spare the solide for the inner cavity of the gearbox, sometimes it jams precisely because the grease is partly dried out, partly smeared on the surface of the metal casing.

How to Repair the Start Button of the angle grinder

Repair of angle grinder must begin with clarification of the malfunction, to find what specific node is out of order. Delema find out the nature of the fault, what exactly is out:

  • If there is a spark when you turn it on, the housing gets warm, and when you turn it on, it starts to smell like fumes. In this case, there can be two options. the collector is dirty or the collector is burned out.
  • if the angle grinder doesn’t turn on at all. you have the following options: power cable is broken, the trigger is broken, worn brushes.
  • If the drive develops and the engine goes “off”. it is a shorted winding in the stator.
  • if during the operation of the angle grinder, there is an unusual mechanical sound. it happens when the gearbox is worn

The main nodes in the angle grinder is: the stator, armature and gearbox. There are windings on the stator, which are divided into two sectors. Anchor, which is the moving part of the angle grinder, also consists of windings. Gearbox. a device for transferring rotation, serves to contain the speed of rotation within the given limits.

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Also allocate devices that also come into disrepair: the collector, it is a plate located on the armature, isolated from each other. Brushes. carbon bars in the form of a parallelepiped, they bring current to the collector.

How to Repair a Vibrating Grinding Machine

Disassembled angle grinder easy, rather unscrew the screw on the back side, it is screwed on the plate. When the plate is not secured with a screw, the shroud is removed. Here are placed the armature with the stator, but the reducer is under the hood of metal, this part of the device mainly and heats.

Angle grinder does not turn on. repairing! Interskol 115/900 angle grinder.

When the collector, which is mounted on the armature, malfunctions, sparking, burning odor and overheating of the shroud. The cover has been removed, now we need to remove the armature and manifold. At first, you must remove the brushes from the grooves, which are held in place by springs. With the installed gearbox is difficult to do so, so the gearbox must also be disconnected. Only later of course pull out the armature, this must be done carefully. Otherwise it may tear the bearing, it is on the back side of the armature shaft. And we check on integrity of a collector, we clean plates from pollution. For which the design of burnout plates, the collector must be replaced with a hundred percent together with the armature.

does not turn on. first check the power cable for kinks and breaks. Then the button of power on is checked for serviceability. And the 3rd option. the brushes are burnt through, disassemble the angle grinder and examine the brushes. If the integrity is violated. change the brushes. READ How to turn a drill into an angle grinder

The most labor-intensive repair, if came out intervoltage short circuit on the stator windings. When the car accelerates and picks up the revolutions. Here already have to change the winding itself

It is necessary to direct special attention to the fact that the thickness of the wire must match, the density of the winding must lie moderately, and the number of turns must necessarily be made idyentically. It is very difficult to achieve evenness manually, use an electric drill, so that the winding is moderately laid on the template

Then both wound coils with coils of the windings installed in the stator, remove the winding wire from the stator, before putting on the ends of the wire for insulation sleeves, suitable to the cross-section.

No power grinder how to fix

repair, stopper, angle, grinder

If there is a mechanical noise inside the angle grinder, it means that the gearwheels are worn out. For this purpose, after removing the housing from the angle grinder to disassemble the gearbox itself, unscrew the 4 screws from the hood. Occasionally there is a noise inside the housing due to the lack of lubrication, when our customer is still a tooth on the gears are intact. Then you just need to add solide, and the noise will disappear. If there is damage and the teeth are chipped, it is time to change the gears

It is important to remember that the gears on the bolsters with 1100W power are different from the gears on the bolsters 1500W. Straight-toothed are on the first type of machines, but on the angle grinder 1500W. gears with beveled teeth

That’s why they are not interchangeable, it is not easy to remove the gears, for this purpose, you must use a universal puller. After replacing the gears, lubricate the gearbox cavity. If the grease dries out, it jams and is a prerequisite for breaking the teeth. After repairing the angle grinder, run it without load.

READ How to Cut Paving Tile Without an Angle Grinder

Repair. how to remove and connect Interskol angle grinder button

To understand the construction of the button angle grinder will help the following diagram:

  • The start button is located at position 41 in the housing (pos.47).
  • The start button is energized by the power cable (pos.53).
  • To control the start button (pos.41) angle grinder is equipped with a lever (pos.46).
  • The electric brushes are also connected to it (pos.55) and the special brush holders (pos.44).
  • Also in the electronic part of the angle grinder, where the start button goes, goes the rotor (pos. 31) and the stator (pos.42).

From the scheme it becomes clear that to get to the start button is possible only by removing the handle in the back of the housing angle grinder.

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To repair the start button on the Interskol angle grinder we will need

  • Use a Phillips screwdriver to unscrew the screws on both sides of the handle and remove it;
  • Remove the speed control pad, using a flathead screwdriver to pry up its latches;
  • Using a Phillips screwdriver, disconnect the power cord pins from the power button, having previously removed the clip;
  • Disconnect the four wires from the starter button, which go from the motor and the capacitor to its contacts;
  • Remove the broken button from the housing.
repair, stopper, angle, grinder

Repair. how to remove and connect the Interskol angle grinder button

To understand the device of the angle grinder button will help the following diagram:

repair, stopper, angle, grinder
  • The start button is located at pos. 41, built into the housing (pos.47).
  • The starter button is energized by the power cable (pos.53).
  • To operate the start button (pos.41) The angle grinder is equipped with a lever (pos.46).
  • Also the electric brushes (pos.55) and special brush holders (pos.44).
  • Also in the electronic part of the angle grinder, where the trigger goes, goes the rotor (pos. 31) and the stator (pos.42).

The diagram shows that the start button can only be reached by removing the handle at the rear of the housing angle grinder.

To repair the start button on the Interskol angle grinder, we’ll need it:

  • Use a Phillips screwdriver to remove the screws on both sides of the handle and remove it;
  • Remove the pad to adjust the speed, using a flat screwdriver to pry under its latches;
  • Using a Phillips screwdriver, disconnect the mains cable contacts from the power button, having previously removed the clip;
  • Disconnect the four wires from the starter button, which go from the motor and the capacitor to its contacts;
  • Remove the broken button from the housing.

Useful Instructions. How to Replace the Brushes and Cord of an Angle Grinder

Often the angle grinder company Interskol stops working because of a broken cord, or otherwise wear brushes, for which they almost reach the stator and the device does not work at full power.

How to remove the cord, you already understand from the preceding annotation on the removal of the button angle grinder (with p.1 to p.3). It remains to figure out how to get to the brushes and replace them with new ones.

  • If you have a Phillips screwdriver, unscrew the fixing screws of the handle on both sides;
  • Using the above-mentioned diagram, we find the brush holders, in which the parts we need are placed;
  • Disconnect the brushes from the single electronic circuit of the angle grinder by picking up the tips with a flat screwdriver and simply pulling them out by hand;
  • Put the new brushes in place. If you can not find the original brushes in the stores, it is allowed to take their size a little more than easy. there is a variant to grind them to a suitable size with a rattail. It will not be difficult if the new brushes have different tips. cut the leash from the worn brushes and screw it to the new ones;
  • Insert and screw the cover back on the handle.

After disassembling the angle grinder, it is recommended to blow it from dust using a compressor.

Check also the armature collector, which may be scratched by worn brushes. Clean up the scratches with sandpaper of course.

If your angle grinder does not start when you press start, do not rush to throw it in the trash and get the newest. Most likely, it’s all about the start button, when repairing you will not be special abilities and knowledge. Replacing the button for the Interskol and other companies angle grinder is much cheaper than buying the latest angle grinder.

How to Disassemble a Gearbox Properly: Recommendations

When the gearbox completely refuses to work, it needs to be completely disassembled to replace parts and thoroughly cleaned. Prepare the bench press for the work. All work is done in a specific process sequence:

  • The bolt holding the gear housing is unscrewed with a wrench.
  • The rotor housing is fixed in a vise with great care.
  • Making soft blows with a hammer, the body is removed.
  • The rotor position is good for removing the bearing. Bowls clamped again.

Putting a block of wood, the bearing is knocked out. Remove the pinion from the gearbox axle:

  • Wrap a cloth around the rotor and secure it in a vise.
  • The gear is also wrapped in rags with a wrench, turn it counterclockwise.

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