It should be noted that the small size of the mechanical part of the tool somewhat complicates the process of repairing the tool, so be sure to be careful when carrying out repair work.
Unlike drills, screwdrivers operate primarily on batteries. This means that different motors are used in the construction of these tools. Determining the malfunction of the electrical part of the screwdriver is not difficult. If the battery is charged, but when the "Start" button is pressed, the sound of the electric motor is not heard, then the cause is a breakdown in the electrician. Consider the main types of electrical screwdriver malfunctions.
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Now you know the main signs and types of screwdriver malfunctions. To repair it, you do not need to be a specialist, but just stock up on tools and free time.
A screwdriver is a tool often used in the professional field during repair and construction work, as well as in everyday life. Like any electromechanical device, screwdrivers are prone to malfunction. This device is not a complex device, and in the event of a malfunction, the repair of the basic malfunctions of the screwdriver can be done by hand.
Below is a figure showing the internal structure of the battery device.
In screwdrivers, both collector electric motors and brushless motors (do not have electric brushes) can be installed.
If your screwdriver breaks down, then the malfunctions of this unit may be as follows.
All faults, except for the electrical plug, can be eliminated only after disassembling the device.
To disassemble the device, follow these steps:
disconnect the battery pack from the body of the device;
unscrew all the fasteners holding the 2 halves of the device together;
remove the upper part of the case;
remove all contents from the body of the device;
carefully disconnect the start button from the case without damaging the wires connecting it to the engine;
remove the speed switch;
disconnect the motor, gearbox, coupling and cartridge by unscrewing 4 screws;
To unscrew the cartridge, you need unscrew the screw , which can be seen inside the mechanism when the cams are open. Unscrew the screw clockwise as it has a left-hand thread. After that, the chuck must be unscrewed from the gearbox shaft by turning it to the left (right-hand thread).
If you have a battery pack, the first step is to check the batteries in the battery pack by disassembling it. There are collapsible and non-collapsible blocks. In the second case, you will need to carefully insert a screwdriver into the place where the block walls are glued and, slowly, separate them.
Further, it is necessary measure voltage on all "banks". The voltage rating is indicated on the case of each battery. The voltage should be slightly lower than indicated, but the same on serviceable batteries. Defective batteries will differ significantly from the rest in terms of voltage output - they will need to be replaced. New batteries can be purchased online.
It is important to solder them correctly, that is, in series: the plus of one battery is connected to the minus of the other, and the plus of the second with the minus of the next, etc.
If you are the owner network screwdriver , then the verification algorithm is somewhat different. First, you need to unscrew the body of the device and remove one half of it.Take the tester and ring the power cord for an open. In the case of a working cord, you need to check the start button. With the button pressed, check if there is a circuit on its output contacts. If the button is faulty, it will need to be replaced or repaired. How to do this will be discussed later. With a working button, the problem may lie in the electric brushes or the motor.
Below is the electrical diagram of the cordless screwdriver.
It can be seen from the diagram that 2 wires from the battery are suitable for the button, and 2 wires go out of it to the engine. Also, 3 wires are connected to the button from the transistor, which is responsible for adjusting the speed. To understand the structure of the screwdriver button, it must be disassembled. All wires going to this part do not need to be unsoldered. They will not interfere with disassembly.
Take off push mechanism (red) from its seat. Do this with gentle rotational movements, while simultaneously pulling the part in the direction opposite to the button, being careful not to break the jokes.
Next, remove button cover ... In the places indicated by the arrows in the figure, using a knife and a screwdriver, it is necessary to pry and push out the latches, and then remove the cover.
Removing the cover, you will see reverse compartment ... But the button mechanism will still be unavailable. Using a soldering iron, separate the 2 elements (indicated by an arrow in the next figure).
Carefully pull out the element numbered 1, then remove the cover that covers the compartment with the device turning on mechanism.
Holding the return spring, remove the mechanism from the case.
In the faulty button, you will see the erased pads.
Contact pads wear out quickly due to the poor quality of the metal. Fine metal dust from worn out contacts accumulates between them and closes the pads. As a result of this, a spontaneous start of the apparatus occurs.
Remove metal dust using cotton wool dipped in alcohol. If this fails, you can scrape it off with a knife. After these actions, the spontaneous start of the device will stop.
If the speed regulator does not work, then the transistor has burned out, which must be replaced.
To check the condition of the brushes, you must disassemble engine , bending back the "antennae" located at the end of the body.
Then, with light blows of a hammer on the motor shaft, knock the rotor out of the housing.
In this case, first, the cover is removed, in which the electric brushes are located.
The next photo shows that the collector has black color ... This means that it will get dirty with dust from the brushes. As a result of contamination of the collector, as well as the grooves between its plates, the engine power decreases and the brushes spark. It is necessary to wipe the collector with cotton wool soaked in alcohol and clean the grooves with a needle.
The following photo shows what a clean manifold looks like.
If the brushes are worn out, they will need to be replaced. Some models of screwdrivers are difficult to find on sale original brushes ... But you can find brushes that are suitable in size, then trim them on a grinder and connect (solder) to the brush holders.
Sometimes, in order to replace the brushes, you will need to saw a groove in them. It depends on how you attach them.
To better understand how the brushes are replaced, you can use the following video.
The engine brake is a device that stops the rotation of the armature at the moment the start button is released. In screwdrivers, this function is implemented by closing the plus and minus of the motor when the button is released. As a result, a large self-induction occurs, and there is spindle lock (with a lot of sparking from under the brushes). If the engine braking does not work, then it will be necessary to replace the regulating transistor or start button.
Mechanical failures of the screwdriver include malfunctions of the ratchet, gearbox and chuck of the apparatus.
If the ratchet does not work on the screwdriver, then you will need to disconnect it from the gearbox for troubleshooting. Sometimes special rods are installed in the coupling, which regulate the force, and in some devices, instead of rods, 2 balls are installed in each hole. They are pressed by a spring, which, when the adjusting ring is twisted, presses on the balls.
In most cases, repairing a screwdriver ratchet consists in cleaning its components from dirt and applying new grease.
If unusual noises are heard in the gearbox, or the spindle rotates in jerks, with slipping, then the failure of the gears of the mechanism, the worn-out teeth on its body, may be the cause.
Gears most often break if they are made of plastic (used in cheap machines). If this happens, then they must be replaced.
In the next photo you can see the device of the gearbox.
The reason that the spindle does not rotate when the engine is running may be the wear of the plastic teeth inside the gear housing.
To restore the mechanism to work, it is necessary to disassemble the gearbox (it is better to photograph the disassembly process) and screw it in place of the worn teeth small bolt , ground down to the required size. The place where you will install the bolt must be screwed. It should be located strictly opposite the plastic tooth located on the inside of the case.
Make such markings on the back of the case, opposite the first one.
Next, drill holes in the marked places.
Screw the bolts of the required length into these holes, having previously grinded off so that they are flush with the other plastic teeth. After adjusting the bolts, you can assemble the gearbox with the required amount of lubricant on the gears. This completes the repair of the screwdriver gearbox.
To start repairing this unit, you must first remove the chuck from the screwdriver ... For this, a complete disassembly of the screwdriver is not required. How to unscrew the keyless chuck is described above.
Frequent chuck malfunctions include incomplete output of one of the cams, as shown in the following photo.
The cause of the malfunction may be worn out thread on the nut clamping the cams, or worn teeth on the cams themselves. To verify this, you will need to disassemble the cartridge.
Disassembly and repair of the screwdriver chuck is done as follows.
It is necessary to hit with a hammer on the part protruding in its center. In order not to deform this part, you can lay a small piece of wood.
The top section will not be enough and further chuck disassembly will be required. To do this, lightly clamp the bolt into the cams and hit it with a hammer.
When the inside of the cartridge falls out, its analysis is complete. You will see nut consisting of 2 halves ... Most often, malfunctions in the chuck arise from this part. The thread on it wears out and the cams slip when tightened. Therefore, there is an incorrect centering of the latter.
Also, the thread can be worn on the cams, which, like the nut, must be replaced. But if you do not find the necessary parts to change them, then you will need complete replacement of the cartridge ... When assembling the cartridge, the cams must be installed at the same level, in a compressed state, after which a nut consisting of 2 halves is put on, and after that the whole structure is placed in the body. When the malfunction is eliminated, you can assemble the screwdriver.
In practice, finding spare parts for a cartridge is troublesome. It is easier to buy a new chuck, since its price is not so high, within 300 rubles.
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It is not difficult to replace the battery of an electric screwdriver (screwdriver) type BOSH IXO on your own.
This requires tools and materials:
1. Unscrew the BOSH IXO case.
2. We take out the old battery from the case. As a rule, it is glued to the glue, so we carefully pick it up, and then we solder (bite off) the contacts. Attention ! Before unsoldering, remember the polarity (where is plus and where is minus)
3. We tinker the contacts of the new battery. How to do it correctly, see my video “Tinning the contacts of Li ion batteries”.
4. Solder the new battery to the BOSH IXO wires.
Have you ever faced a situation where you need to finish work urgently and one of your most essential power tools suddenly breaks down? In this case, the first thing that comes to mind is to run to the repair shop or, at worst, to purchase a new device. An attempt to fix the breakdown on their own seems to many to be impracticable due to incompetence.
In some cases, of course, one cannot do without the help of a specialist or the purchase of a new instrument, but quite often the problem is not so great that it cannot be solved on its own. You just need to first familiarize yourself with the information regarding the internal structure of the device and methods for eliminating possible malfunctions.
As an example, I would like to present a sequence of actions on how to repair a screwdriver with your own hands in the event of one of its common malfunctions. We will talk about a specific model of the Einhell as 18-2 GA cordless screwdriver, the chuck of which has stopped, despite the correct operation of the drive mechanism, and can be easily rotated by hand.
Sometimes the problem lies in the speed switch, which may be in an intermediate position or the lever it moves has not completely moved the ring gear. It's easy to fix by toggling it back and forth a couple of times. If this does not help, then the malfunction, most likely, needs to be looked for in the gearbox. Do not worry about the daunting task of repairing a screwdriver gearbox. In fact, the device of this power tool is quite simple and you do not have to go into the jungle like a nesting doll.
To get to the gearbox, it is necessary to disconnect the battery and remove the upper part of the power tool body, having previously unscrewed the 9 mounting screws with a Phillips screwdriver.
After removing the top cover, you will see several interacting mechanical and electrical blocks and parts, including:
Permanent magnet motor;
Three-stage planetary gearbox;
Two-position speed switch;
Spring loaded lever driven by speed switch;
A transistor that regulates the supply of voltage to the motor and is responsible for the smoothness of the speed of its armature;
A start button having a wide-pulse regulator for transmitting a control voltage to the transistor;
Engine rotation direction switch (reverse);
Lever that moves the reverse switch;
Battery terminals;
Ratchet, limiting the level of load on the cartridge;
Self-clamping chuck.
To get inside the gearbox, you first need to disconnect the electromechanical stuffing of the screwdriver from the bottom of the case, which can be easily done, since the parts are not fixed.
Then you need to unscrew the 4 screws holding the two halves of this mechanical block, but it is better to do this by placing it vertically.
When the fasteners are unscrewed, carefully (so that the contents do not fall out of the plastic case) disconnect the two parts of the gearbox from each other, trying to ensure that the separating washer separating the first two gear stages from the third remains on the half that interacts with engine.
Thus, while maintaining the integrity of the first and second stages, in the design of which there is no point in interfering with a given breakdown, you can focus on the third stage, the state of which will help you understand what the problem is and how to repair the screwdriver on your own.
As you can see in the previous photo, three small gears (satellites) belonging to the third stage of the planetary mechanism are in a chaotic state. Their pins (axles), possibly due to strong vibration, loosened and fell out of the holes intended for them, therefore the shaft driving the chuck does not interact with the gearbox and therefore rotates freely.
Further actions will be aimed at returning the pins to their place, for which they first need to be removed from the gears.
Then the axles, as well as the holes for them, should preferably be wiped off the grease and treated with a cotton swab dipped in solvent.
Then hammer the pins into the holes using a hammer and a guide metal object.
When the axles are in a stationary state, you can put gears on them and begin the process of assembling the power tool in the reverse order to that described above.
Video (click to play).
Of course, other types of malfunctions may arise, therefore, in each specific case, you need to additionally look for information on how to identify the problem and how to fix the screwdriver in case of a given breakdown, and if you are determined, then your efforts will most likely not be in vain, so how they will save time and money.
