Breakdown Detection And Repair Of A Grinder, A Detailed Video About The Repair Of Angle Grinders

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Video: Breakdown Detection And Repair Of A Grinder, A Detailed Video About The Repair Of Angle Grinders

Video: Breakdown Detection And Repair Of A Grinder, A Detailed Video About The Repair Of Angle Grinders
Video: Angle Grinder Diagram - How does it work 2023, September
Breakdown Detection And Repair Of A Grinder, A Detailed Video About The Repair Of Angle Grinders
Breakdown Detection And Repair Of A Grinder, A Detailed Video About The Repair Of Angle Grinders
Anonim
  • A few general useful tips for organizing a grinder repair
  • How to remove a needle bearing or a destroyed sleeve bearing race
  • How to remove the helical gears of the grinder reducer
  • Features of designs of foreign manufacturers of angle grinders
  • Repair of angle grinders Bosch
  • Repair of angle grinders Hitachi
  • Makita angle grinder repair
  • Features of LBM designs of domestic manufacturers
  • Repair of angle grinder Interskol
  • Repair of angle grinder Lepse
  • Repair of angle grinder Fiolent
  • What do-it-yourself grinder repair can a user do?
  • Systematization of faults in the electrical part of angle grinder
  • Grouping of faults by mechanical part of angle grinder
  • Simple malfunctions and DIY diagnostics and elimination methods
  • Do-it-yourself complex malfunctions and repair of angle grinders
  • A few words about lubrication
  • Video block on the repair of grinders - typical malfunctions

This article suggests ways to find faults in grinders of various models and repair angle grinders (angle grinder) with your own hands. Here you can find answers to questions about the procedure for disassembling the gearboxes of the most popular models of grinders, replacing gears, bearings and their repair. Recommendations are given on the procedure for pressing in and out of gears and bearings, methods of repair and fixtures.

Along with common malfunctions, angle grinders of various brands have their own characteristics. This is due not only to differences in the designs of the grinders, but also from the materials and components used.

It is also important who made the instrument. Knowledge of the features in the design of grinders allows you to repair angle grinders with your own hands efficiently and quickly. The information below will help you repair any brand of angle grinder.

Along with original tools, the construction market was flooded with cheap fakes. And don't think that fakes are made exclusively in China. Power tools from Chinese manufacturers are in no way inferior in quality to manufacturers from European countries or countries of Southeast Asia.

Quality tools from Chinese manufacturers for European consumers go through several stages of incoming control. For third countries, Chinese manufacturers do not carry out tool control. But the tools are made on the same lines, the same factories, the same people. That is why such a difference in price.

To repair a grinder with your own hands, you need to have a diagram of this angle grinder and understand it.

Repairing a Bosch grinder is different from repairing an Interskol grinder. And then there are grinders under the brands Makita, Hitachi, Metabo.

A few general useful tips for organizing a grinder repair

Before proceeding with the repair of the grinder, consider a few useful tips:

  1. Before you start disassembling the grinder, carefully read its description, the assembly diagram and the order of work.
  2. Be sure to follow the sequence of technological operations.
  3. Strictly observe safety precautions.

The most common reason for a grinder to break is a broken wire near the handle. First you need to check the presence of voltage on the button, this is done with an ordinary voltage tester. Then we check the button itself for performance.

In more detail about the diagnosis and repair of the electrical part of the grinder.

How to remove a needle bearing or a destroyed sleeve bearing race

Various bearings are used in the gearboxes of the grinders. They are subjected to heavy loads and are the cause of malfunctions.

Bearing failure is determined by increasing spindle shaft play. After disassembling the gear housing and removing the large gear shaft, you will see the needle bearing.

The needle bearing is not used in all grinders. In the same grinders in which it is installed, its dismantling can be done in several ways.

After removing the damaged part of the bearing, the inner race can be removed using a machine tap. Clamp the machine tap of a suitable diameter into the screwdriver chuck and try to screw it into the bearing race until the tap rests against the bottom of the housing. Continue to slowly screw the tap into the sleeve. He will lift the clip along the thread.

Removing the bearing race
Removing the bearing race

The second way is that the remaining cage of the destroyed needle bearing can be removed using a special bolt and a circlip.

How to remove the helical gears of the grinder reducer

Repair of the grinder gearbox begins with the dismantling of the helical gears. It is the gears that become the main cause of the grinder's gearbox malfunctions. In grinders, most often you have to change the small drive gear attached to the rotor shaft.

The helical gear can be mounted on the rotor shaft in two ways:

  1. The gear is fixed with a key connection and clamped with a nut.
  2. The gear is secured with a threaded connection. Moreover, both right-hand and left-hand threads are used.
How to remove the drive gear from the rotor shaft
How to remove the drive gear from the rotor shaft

The large driven helical gear is attached to the spindle shaft in two ways as well:

  1. The gear is pressed onto the shaft.
  2. The gear is secured with a keyway.
Extruded parts of the grinder spindle
Extruded parts of the grinder spindle

In addition to replacing gears in grinders, it is often necessary to replace one or another bearing. And there are at least three of them in the design of the grinder.

Features of designs of foreign manufacturers of angle grinders

In this chapter, we will consider the design features of the grinders produced under the brands Bosch, Hitachi and Makita, as well as do-it-yourself repair of angle grinders.

Repair of angle grinders Bosch

Bosch grinders are a reliable tool that does not cause much trouble to the user. But not every user treats the tool correctly. Repair of Bosch angle grinders is most often associated with the replacement of bearings.

Bosch grinder diagram
Bosch grinder diagram

Structurally, all Bosch grinders are made according to the same scheme. The spindle shaft pos. 25 is pressed into the driven helical gear wheel pos. 26 and rests in the gear housing pos. 821 on the needle bearing pos. 51.

When a bearing is destroyed, a bearing race remains inside the housing, which is not easy to reach. We recommend two ways to dismantle the needle bearing race. These are described in the section "How to remove the needle bearing".

When the teeth are worn out or licked, a pair of gears must be replaced both and only in pairs. When dismantling the gears, remember that the drive gear is attached to the rotor shaft on the thread, and LEFT and fixed with a nut. The driven large helical gear, pos. 26, is pressed onto the spindle shaft, pos. 25.

Repair of angle grinders Hitachi

Hitachi grinders are especially popular with Russian consumers. And this is natural. There are practically no handicraft fakes of Hitachi grinders on the market. The simplicity of the design makes it easy to carry out repairs of any complexity.

Hitachi grinder diagram
Hitachi grinder diagram

Hitachi grinders have increased reliability and rarely end up on the repairmen's desk. The main reason for the Hinachi grinder to be repaired is the breakdown of the gearbox, namely, the production of gear teeth.

The grinder's gearbox is easy to understand. To disconnect the gearbox housing pos. 3 from the stator housing pos. 37, the carbon brushes must be released.

Unscrew the four screws pos. 1 securing the gearbox housing and stator housing. Separate the gear housing and stator housing. The gearbox housing will be disconnected together with the rotor, pos. 8.

To remove the cover of the gearbox, pos. 23, it is necessary to unscrew the four screws, pos. 24. The driven helical gear, pos. 33, is fixed on the spindle shaft, pos. 26, by means of the key, pos. 25, and shrunk with a puller. The bearing, pos. 21, is removed with a puller.

Makita angle grinder repair

A feature of the Makita family of grinders is the quick-detachable protective cover pos.19.

Makita grinder diagram
Makita grinder diagram

Makita grinders are the most frequently repaired. But the reason is the high percentage of counterfeits that have flooded the Russian market.

A real Makita is a reliable, durable tool. But, like all angle grinders, it suffers from the failure of the gearbox and its gears.

Replacing the gears of the reducer is resorted to in case of jamming or destruction.

destroyed pinion gear
destroyed pinion gear

To repair the angle grinder Makita 9069 or Makita 9558 HN, you need to disassemble the grinder.

If the gearbox is faulty, and this is determined by the appearance of backlash in the spindle shaft, jamming of the gearbox, slipping of the driven gear, then the gearbox should be disconnected from the stator housing. Release the carbon brushes, pos. 35, unscrew the four screws, pos. 10, and disconnect the gear housing from the stator housing, pos. 37.

In the next step, unscrew the four screws, pos. 18, holding the rotor cover, pos. 15. The driven gear pos. 14 is removed with the help of a Persian. The pinion gear, pos. 43, is fastened by means of a keyed connection and fixed with a nut, pos. 42. The rotor shaft bearings (pos. 3) are removed using pullers.

Features of LBM designs of domestic manufacturers

Among domestic manufacturers, a special place is occupied by products of such well-known brands as Interskol, Fiolent, Lepse.

Repair of angle grinder Interskol

With proper operation, Interskol grinders can work for years.

Along with the infrequent failure of the grinder's gearbox, in which a pair of gears and a bearing are the weak link, there have been cases of malfunctions in the stator.

Interskol grinder diagram
Interskol grinder diagram

To replace the gears of the reducer, it is necessary to disassemble the gear case, pos. 19, by releasing the cover, pos. 6.

The driven gear, pos. 11, is pressed onto the shaft, pos. 8, and removed with a press. Bearing pos. 9 is removed with a puller.

Repair of the stator of the Interskol grinder can be performed independently if you know the necessary data. When disassembling a burned-out stator, you must calculate the number of turns of the wire used, its cross section.

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Repair of angle grinder Lepse

Grinders under the Lepse brand are marked with MSHU Lepse Kirov 1.8-230-A. These grinders trace their history back to the famous Soviet-made IZH grinder. A surprisingly durable tool that is the most vandal-resistant design.

Lepse grinder diagram
Lepse grinder diagram

The advantages of the Lepse grinder are the ability to replace worn carbon brushes without disassembling the machine body.

Repair of angle grinders Lepse in terms of replacing brushes is simple. Through special windows poz.45, closed with plugs-caps poz.48, carbon brushes pos.47 are inserted into the body of the brush holder pos.46.

When repairing the gearbox of the Lepse grinder, it is necessary to dismantle the gear pair.

The small helical drive gear is attached to the rotor shaft on a key and fixed with a nut.

The driven gear, pos. 15, is screwed onto the spindle shaft, pos. 10, and fixed with a nut, pos. 18.

Repair of angle grinder Fiolent

Recently, the Fiolent grinders have become especially popular. Attracted not only by the affordable price, but also by the reliability of the tool.

Fiolent grinder diagram
Fiolent grinder diagram

Do-it-yourself repair of the Fiolent grinder is recommended to start by studying the emerging faults. If you need to disassemble the Fiolent grinder, then to remove the driven gear pos. 11, it must be pressed out of the spindle shaft, pos. 8.

To remove the spindle shaft bearing, you must first remove the large helical gear. These are minor inconveniences.

Replacing the rotor bearings is associated with the fact that it is necessary to dismantle the small helical gear pos. 22.

What do-it-yourself grinder repair can a user do?

Although the grinder is not a tool of particular complexity, the user cannot perform repair work on all units.

Along with the simple replacement of bearings or gears of the gearbox, there are such malfunctions that cannot be done without special equipment or devices.

  • To press out the driven gear, you need a press. It will not be possible to wind the rotor without devices.
  • Such malfunctions include failure of the rotor. For a simple consumer, such a malfunction ends with a trip to the service center.
  • Advanced users can revive a burnt rotor with certain skills and concepts. But sometimes it's easier to buy a new one than to rewind.

For most users, do-it-yourself grinder repair is limited to a certain range of faults.

Systematization of faults in the electrical part of angle grinder

  1. The simplest malfunction for which the grinder does not turn on is a break in the power wire. The most common breakage occurs in the power cord near the plug or at the entrance to the instrument. The malfunction can be easily rectified by replacing the power cord or removing a broken piece of wire.
  2. Increased heating in the area where carbon brushes are installed. Most often, such a malfunction appears due to the shortening of the carbon brushes below the nominal size. The length of the carbon brushes cannot be shorter than 8 mm.
  3. Sagging of the power button of the grinder. The malfunction is associated with the burnout of internal contacts in the button. Eliminated by completely replacing the switch with a new one.
  4. In some models of angle grinder, a device is used that allows you to smoothly adjust the speed of the grinder. The angle regulator of angle grinder improves the smoothness of turning on the grinder and prevents the working body from biting. Repair of the angle grinder speed regulator consists in its complete replacement.

Grouping of faults by mechanical part of angle grinder

  1. The appearance of extraneous noise in the grinder gearbox, heating of the gearbox. The malfunction is associated with the destruction of the support bearing, wear of the gear teeth of the gearbox, drying out of the lubricant. Eliminated by replacing gears with high tooth wear. If the gear teeth are slightly worn, you can try to fix this. The profile of the tooth is corrected manually by filing with a round file and a drill. The grease is replaced with a new one every time the gearbox is repaired. New grease is applied to thoroughly washed parts.
  2. Replacement of the bearing is required when it is destroyed or a large backlash appears. In some models, the bearing is fitted on the spindle with an interference fit. Replacement requires special equipment, in particular a press. Parts must be cooled or heated.
  3. Replacement of bearings on the rotor is required when large runout occurs. The presence of increased runout is easy to see on the rotor manifold and by the intensity of wear of the carbon brushes.

Simple malfunctions and DIY diagnostics and elimination methods

If the grinder does not turn on when you press the "Start" button, then the check begins with inspecting the power cable at the point of entry into the tool.

Unscrew the grinder cap and check the integrity of the power cord with a tester or phase. Strictly follow safety rules.

If the power cord is intact and the grinder does not turn on, replace the "Start" button.

If the grinder does not work when installing a new button, check the quality of the attachment of the carbon brushes and their tight fit to the rotor manifold.

Do-it-yourself complex malfunctions and repair of angle grinders

The following types of breakdowns require certain knowledge and skills to eliminate them:

  • Seized or ruptured bearings.
  • Licking or destruction of the gear teeth of the gearbox.
  • Open or short circuit in the rotor or stator.
  • Failure of control circuit parts.
  • Destruction of the gearbox housing.

A few words about lubrication

The reliability of the gearbox and its durability largely depend on the timely replacement of the lubricant and its correct selection.

There is a wide range of lubricants on the Russian market for fuels and lubricants. Among them, lubricants from Russian manufacturers stand out.

Lubricant for reducers of grinders from Russian manufacturers
Lubricant for reducers of grinders from Russian manufacturers

Modern tool manufacturers strongly recommend using only their own lubricants. This is the manufacturer's policy.

We recommend using lubricants specially developed for gearboxes from Russian lubricants.

But the quality of the grinder is influenced not only by the correctly selected lubricant, but to a greater extent by its timely replacement! Do not tighten when changing the lubricant, monitor its condition.

Video block on the repair of grinders - typical malfunctions

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