Diagnosing Parts for Power Tool Repair

To better understand how to diagnose your power tools, it is important to first know how they work. Although your tools and their motors can be intensely complex machines, becoming familiar with the basic functions and pieces of your tool’s motor is not only important but surprisingly simple as well.

Firstly, your power tool receives and delivers power just like water moves through a series of pipes, out of your sprinkler heads, and then onto your lawn or garden. If said water doesn’t come sparkling from your sprinklers to the earth, you can sure be a problem has occurred somewhere along its path of movement. In theory, problems in your power tools occur, and can be diagnosed, in exactly the same way. Electricity follows a distinct path in your power tools; it enters from a power source and travels along an electrical path of wires and connectors to the tool’s motor where it is converted into actual physical power. That power is then expelled at the opposite end of the tool in the form of a spinning chuck or saw blade.

The electrical path begins, of course, with a power source like a battery or power cord. Once this source is activated electrical energy travels through the power cord to the tool’s switch or trigger which will either make or break the electrical flow that powers your tool. After surging through the switch, the electrical path (in a nutshell) runs through the tool’s carbon brushes, into the armature (more specifically, its commutator bars), and lastly, the energy moves into the field where is ultimately converted into real physical force. To diagnose a problem in your power tool, simply start at the power source and follow the electrical path.

Fortunately, because the first components along the electrical path are more likely to experience the wears of power surges or excess heat, problems occurring early in the electrical path are far more common than those that occur deeper within the tool. Additionally, your field and armature are much more heartily fabricated than are your standard brushes and switches, but, I digress. To get more properly down to business, I’ll begin at the beginning and talk a bit about power cords.

Usually, it’s pretty darn apparent if you have cord damage. This will look like cracks or breaks or other visible wear and tear and will cause over-heating and loss of power. If the cord is damaged, it acts like a minor/major kink in a garden hose or clog in a water pipe and the cord can not deliver adequate electrical flow to the tool’s motor. This means the tool will have to work significantly harder to perform which will, in turn, cause the motor to heat-up which will eventually cause damage to the tool’s parts. As worn or broken power cords are also an electrical hazard, they should always be replaced. Note: The same “kink” or “clog” phenomenon will also occur where a too long extension cord is used. Because electrical energy depletes as it moves along its path, too long extension cords will deliver less energy and over-heat your tool. Always use the shortest length extension cord possible.

After checking the cord, move on to the switch. Here, heat damage is fairly simple to detect – the wiring will be melted or discolored or the actual plastic of the switch body will be appear burnt or melted. If the power switch has shorted or failed, the electrical path will stop there and the tool will not engage. Tell-tale bad-switch symptoms usually come in the form of troubled starts, over-heating, and a noticeable drop in your power tool’s performance and overall power. If the switch is properly connected and you can’t see any visible damage, move ahead to the tool’s brushes.

Brush damage can cause difficult start-ups, on/off action during use, a general lack of power, excess heat, or some bad smells or sparking. Additionally, a failing brush can sometimes keep your power tools from starting altogether. With your brushes damage usually occurs in one (or more) of the following forms: heavy wear, chipping or crumbling, burrs, or heat damage. It is hard to say which is most common, but I’d wager it’s the wear and tear; some brushes have wear-lines to indicate when the brush requires replacement, however, it’s a pretty good rule of thumb that when the brush’s carbon block wears to about a quarter inch in thickness, it needs to be replaced.

Chipping occurs when the carbon becomes abnormally damaged or begins to crumble inside the tool. As the name implies, a chipped brush will have a chunk missing from the carbon. Burrs, on the other hand, are terrible little creatures that can form around your brushes blocking or preventing the connection between brush and commutator. These can usually be scraped away, but it’s still important to ensure your brushes are in otherwise good condition – as long as you’ve cracked into the motor, you may consider replacing burred-up brushes anyway.

Also verify the springiness of your brush’s spring tail. If said springiness is gone, your brushes will lack the required pressure to maintain contact with the armature. Lastly, heat-damage on your brushes will look precisely as you’d expect, you will see burn spots on the carbon or other forms discoloration on the spring and wires. Chipping, crumbling, heat-damaged, or heavily worn brushes all require replacement.

While you’re here at the brushes though, it’s a great opportunity to continue down the electrical path to your armature and its commutator bars. Together, the commutator bars should form a complete and perfect circle, if there are any bumps, divots, or missing bars, this could account not only for chipping brushes but for start/stop action as well. Also, look for discoloration or heat-damage on the commutators and take a visual inventory of the rest of the armature assembly. If the assembly has endured any heat-damage, this can significantly effect the performance of your power tool. Heat-damage, of course, can be identified by any discoloration, burning, and/or melting on the armature assembly. Armature damage can additionally cause high-heat, low-power, or smoking or sparking during use.

Now, if only by process of elimination, you know the electrical path has lead us to the tool’s field, which, despite its toughness, is a delicate and extremely vital part of your power tool. Like with your armature, heat-damage from misuse will manifest on the field as discoloration, burning, or melting of its wiring and/or insulation. It is also sadly common for a field to crash after being pushed too hard by its operator. When tools are forced to work on projects that exceed their design, or if inadequate power is flowing through the electrical path, a field can quickly go kaput. Failing field symptoms include over-heating, a significant loss of power, and smoking or sparking during use. Note: Because fields and armatures are both expensive and more difficult to replace, it’s important to treat your power tools right. Don’t misuse or abuse them, keep them adequately maintained, and repair them when they need it.

Finally, now that you know what to look for, there are a few things to keep in mind as you work with and diagnose your power tools. First, just like energy runs down the electrical path in your power tools, so does damage. Within your tool, any suffering component can have a domino effect that will damage neighboring tool parts along the electrical pathway. Hence, it is extremely important to isolate your problem(s) and repair it before it spreads to the tool’s other components. Secondly, keep in mind that all of these malfunctions can feel very similar from the outside and that they may occur singularly or in any combination. Be familiar with your power tools and learn to understand their subtle cues. This will help you repair your power tools at the first signs of drag or malfunction. Lastly, as we all know, it is better to solve your small problems before they become full-blown disasters. Love your tools and I promise they will love you back.

If problems persist after repair and diagnosis, take your tool to an authorized power tool repair center for professional inspection.

Click here for a step-by-step guide to replacing the brushes in your power tool.

Click here for a step-by-step guide to replacing the switch in your power tool.

Makita Compressor AC310H

Makita has just released their new 2.5 HP high pressure air compressor – the AC310H, a sleek and compact machine with surprisingly big, efficient power. To begin, the compressor is engineered with a surplus of innovative technologies, and, of course, the AC310H is built with the same nearly invincible components and the indestructible fabrication Makita tools have become famous for. With new technologies the compressor is able to deliver 400 PSI to accommodate the most advanced pneumatic tools. Additionally, the compressor’s dual capacity design incorporates two universal couplers for standard nailers and two specialized couplers for high-pressure models. Although the compressor’s big Makita power is compact into a 1.6 gallon tank, the machine still provides the same power capacity as a 5 gallon tank at 120 PSI. The machine additionally boasts a flabbergasting 1,720 RPM which allows for much greater displacement at a much lower rate of RPM. This innovation is also responsible for reduced noise emission and consequently a more comfortable working environment.

The AC310H also flaunts an improved performance and much faster recovery time with an efficient dual-head (2 stage) pump, and with a low amp draw, chances of a tripped breaker or voltage drop during use are dramatically reduced. The tool’s pump is also oil-less; this means you get a truly superior performance without the hassles of constant maintenance and monitoring. Lastly, the tool’s four-pole induction motor is not only gorgeous, but it provides the ultimate in durable efficiency, and with it’s roll cage and kick plate construction, the compressor is perfectly prepared for the obstacles of jobsite life. The AC310H is an incredible compressor, and as it’s built for fantastic convenience and with the big power to support any industrial tool, this is one machine that belongs at the top of every craftsman’s wish-list.

Follow me to view other Makita Compressors.

The Benefits of Buying Reconditioned

Buying factory reconditioned tools is a great way to save money and gain an expert power tool. You see, after being rigorously inspected, restored, and rebuilt, reconditioned tools come with the same warranty and same high-performance standard as their non-reconditioned counterparts. Recons, however, deliver that high-performance and industrial grade power at a fraction of the price. For some of the best bargains in the industry, look no further than factory reconditioned.

Follow me to read more about the benefits of buying reconditioned power tools.

Inspired by fellow craftsmen and an environment in the throws of pandemonium, M&M Tool and Machinery and Toolsandmachinery.com urge others in the power tool community to be more environmentally conscious. Repairing power tools rather that replacing them is a simple and effective way to give back to the environment, and a smart way to be economically responsible.

Salt Lake City, UT - June 17, 2010 — With our planet in environmental turmoil and the economy not far behind it, more and more people are considering the ramifications of their consumption and the options for leaving behind a smaller carbon footprint. Accordingly, there is now a fresh influx of Green and environmental campaigns earnestly convincing the populous to live smarter and give back to the environment. Because that environment is the foremost factor in the success or failure of the power tool and woodworking communities, craftsmen all over the country have began a Green-living movement of their own. 

Craftsmen rely heavily on our Earth’s natural resources and as these resources continue to deplete, so do future prospects for many of today’s woodworking community. “Green is the new black,” says Mallory, the self-proclaimed environmental enforcement officer of M&M Tool and Machinery, “it has never been more important to be environmentally conscious, and craftsmen are the perfect niche population to spearhead a movement in the Green direction.”

All those in the power tool industry know that power tools are an expensive investment, that woodworking is an expensive pastime, and that unlike our favorite cedars, maples, and pines, money does not grow on trees. These days it is crucial that we conserve both. “Repairing your power tools before you replace them is one of the smartest things you can do as a craftsman,” says Mike, a woodworking extraordinaire at M&M Tool and Machinery, “craftsmen can usually repair tools on their own, and refurbishments are a much more affordable option when compared to investing in tool replacements.” Repairing power tools is economically smart, and as these repairs can potentially keep millions of power tools from seeing a landfill each year, repairs are environmentally smart as well. Even small repairs have the ability to drastically reduce carbon output, waste, and consumption; over time, it seems, repairing power tools with replacement parts can make a significant environmental and economic difference.

Josh of M&M Tool posits that repairs and refurbishments for power tools and machinery might just be the extra push the power tool industry needs to revitalize itself. “We have thousands of Dewalt tool parts, Porter-Cable parts, Makita parts and many more in our inventory just waiting to revive your power tools,” he says, and because M&M Tool is so firmly behind the Green power tool repair movement, “repair estimates are always fast and free, and our repair costs are low as well.” At M&M, it is believed that in the woodworking community, power tool repairs have a ripple effect that ensures extra money in the pockets of busy craftsmen, a reliable power tool in-hand, and perhaps most importantly, one that ensures work on the agenda.

“It is our obligation as craftsmen and as people to respect the resources that keep us in business,” says Mallory, “if we pollute the Earth into oblivion, there will be nothing left build on or build with; at very least, our Earth and our projects won’t be nearly so beautiful.” Essentially, the Green frame of mind is catching hold of craftsmen everywhere, and at M&M Tool, is has catalyzed a movement to economically repair power tools and promote environmental friendliness. 

Click here for more information about how to change the brushes in a power tool.

Click here for more information about how to change the switch in a power tool.

M&M Tool and Machinery and their sister corporation Toolsandmachinery.com and are a family operated company in the heart of Salt Lake City, UT. For over seventy years M&M Tool has sought to provide the best knowledge and information, and the most expertise to the tool industry. Through providing replacement parts, in-house service, and warranty repair to all power tools they sell, M&M Tool has established themselves as a trusted global supplier of power tools, woodworking machinery, and all their working parts. For more information about M&M Tool and Machinery, or any of the thousands of products they carry, please call 866-485-8200, or visit their website at toolsandmachinery.com.

For nearly a century Dewalt has provided innovative solutions to the power tool and woodworking communities. Now, having recently launched a new line of intense XRP and lithium ion power tools, Dewalt is again carving its influence into the history of power tools and the into lives of the power tool-lovers who use them.

Throughout the tool industry, Dewalt products are know for their strength, durability, and overall high-performance. The company itself is know for providing more effective answers and better solutions to the tool industry’s many crafting and woodworking obstacles; now, after years of trailblazing, Dewalt is becoming known also for their superior XRP and lithium ion technology as well.

Consisting of a series of drills from hammer drills and impact drivers, to right angle drills and and drill drivers, each tool in Dewalt’s new line-up has been completely redesigned to accommodate an evolved network of builders, building styles, and technological expectations. Theses drills are now more compact, lighter weight, more comfortable, and perhaps most importantly, the drills are now more efficient as well. Utilizing a patented three-speed transmission designed to provide optimal power to each different application, and with an intensely efficient frameless motor engineered to produce a virtually unparalleled performance, Dewalt’s XRP line and lithium ion drills are a force to be reckoned with. According to M&M Tool’s Josh, “these new Dewalt tools are seriously comfortable to use, they pack a surprisingly big punch for their compact size, and with crazy-good innovations, the tools work like nothing else we’ve seen from Dewalt.” 

Additionally, and while wearing a Dewalt t-shirt, M&M Tool’s Corbin adds that, “from the new 18V line-up, the Dewalt DCD950KX 18V Cordless XRP Hammerdrill/Drill/Driver Kit and Dewalt DCD940KX 18V Cordless XRP Drill/Driver Kit are virtually unbeatable.” Corbin goes on to say, “M&M Tool and Machinery, and our sister on-line company, toolsandmachinery.com, are proud to continually support Dewalt power tools, and Dewalt parts and products.”

Overall, Dewalt’s improvements to their lithium line result in superior efficiency, a 30% increase in runtime, and an impressive decrease in charging time as well. In fact, the new lithium ion batteries are designed to completely charge a power tool battery in just 30 minutes. Also, being compatible with Dewalt’s former 18v line-up from 1996 to present, lithium or not, the battery and charger system provides reliability, peace of mind, and and the security of Dewalt’s time-honored performance. “Dewalt’s new lithium ion batteries are extremely compact; they weigh just about one pound, and with developing battery technology, the batteries are fast-charging, long-lasting, and totally reliable,” says Kris, a long-time power tool aficionado and M&M Tool veteran. 

Ultimately, Dewalt is bringing down the proverbial house with their recent XRP and lithium ion power tool launch, and vendors and consumers alike are animated about the new line; Mark, in fact, a loyal patron of M&M Tool and Machinery, claims he is thrilled about replacing his former cordless drill with Dewalt’s DCD970KL 18V Cordless XRP Li-Ion Hammerdrill/Drill/Driver Kit, “a power tool for a real man,” or woman, of course.  

This splash is likely to continue making significant waves in the power tool community, and with such an untarnished, and absolutely respected track-record, Dewalt is expected to continue reinventing the power tooling and woodworking atmosphere as we know it.  

M&M Tool and Machinery and their sister corporation Toolsandmachinery.com and are a family operated company in the heart of Salt Lake City, UT. For over seventy years M&M Tool has sought to provide the best knowledge and information, and the most expertise to the tool industry. Through providing replacement parts, in-house service and warranty repair to all power tools they sell, M&M Tool has established themselves as a trusted global supplier of power tools, machinery, and all their working parts. For more information about M&M Tool and Machinery, or any of the thousands of products they carry, please call 866-485-8200, or visit their website at toolsandmachinery.com.

There are a surplus of things that can go wrong with your power tools, this is widely known; what is less known, however, is just which thing is wrong at which time. Fortunately though, there are a few tricks to help you know just which component in that intricate parts conglomerate is presently your weakest link. Take your switch for instance, this is a part that may seem nondescript or inconsequential, realistically though, the switch is a vital piece of your power tool’s performance and a variety of spooky things will begin haunting your power tool should its switch be kicking the bucket.

The first symptoms to arise will come in the form of malfunctioning or failing start-ups. You will attempt to activate the tool and as if life has simply left it for greener pastures, the tool will be absolutely dead, or, at least, it will require several pumps and perhaps a joggle or two to revive itself. Overtime, it is regular wear and tear on the switch’s interior connections that causes these, well, incomplete connections and consequently your incomplete start-ups as well. This wear and tear will also effect (in no particular order) the performance of your tool when it does activate. You will likely experience a decrease in the tool’s normative power as little bits of the tool’s juice or energy is lost in transmission. Such malfunctions may also be caused by a switch battling heat damage, therefore, simply relying on the newness of your power tool or the infrequency of its use may not always be the most accurate reference frame.

If these symptoms are left untreated or undetected, the switch will simply short-out completely and start-up (and obviously use as well) will be impossible until the switch is replaced. Although a switch replacement is a reasonably achievable repair process, or at least a relatively inexpensive one, it is always best to settle all disputes with a good-old-fashioned visual inspection. Normally, it can be very clearly seen if your switch has suffered any heat damage – the interior wiring will be discolored, or the wires and connectors may appear burned or melted. If there is no visible heat damage or other untoward appearances, it is likely the switch itself, with all its own wires and gizmos, has simply met (or is very close to meeting) its maker.

Replace the switch, or have it replaced by a technician, and you and your power tool should be back on the high-road in no time. If, however, you still have problems with start-ups or with weak performance, I suggest checking your carbon brushes. If your brushes appear to be in fine working order, there could be a more serious problem. Take the tool to a authorized power tool repair center for a more thorough inspection.

In summary, if you tool has trouble starting, or if you notice a decrease in its regular power or performance, its likely your switch needs to be replaced. Remember though, to always take good care of your power tools and these part replacements will be far fewer and further between.

Click here to read about how to replace the switch in your power tool.

There is a long list of things that can go wrong with your power tools, from gears or bearings, to switches and brushes, any working parts in your power tools have the potentiality to go kaput. Despite all the obstacles of power tool diagnoses though, there are a few tell-tale signs to indicate the time has come to replace your brushes.

Before we begin though, I will digress for a moment to give a little shout-out to power tool brushes: despite their small size, your carbon brushes are essentially the backbone to any working motor; they are the tie that binds your power tool and its components, the bridge that allows your power tool perform at its peak, and they will literally wear themselves to nothing to ensure your jobs get completed better. Its a hard-knock life to be a power tool brush, and although it is the nature of brushes to wear slowly, gradually over time, it is because they work so hard that you can so accurately perceive when your brushes require replacement.

Firstly, your power tool will usually loose the spring in its step. For example, you may need to joggle or shake the tool to achieve activation, it will likely loose RPM and energy during performance, and the tool will usually emit of smell of “malfunction” or burning. You may notice more sparking than is usual for you power tool; by peering through the motor’s cooling vents, you can usually keep a consistent eye on any sparking, usual or unusual, that occurs within the motor. Additionally, if the tool stalls or cuts-out during use, it is very likely your brushes have simply worn themselves out.

Although it’s a generally fail-safe game-plan to wait for your power tools to show you it’s time for a brush replacement, it may not always be the wisest option. As with any other power tool component, it is important to maintain and monitor your brushes. This, of course, is not necessary with every use, but periodically (depending on degree and frequency of use) it is beneficial to take a quick peek at the tool’s brushes. As a general rule, if either brush has worn to about a quarter inch long, it is time to replace it. If the carbon (a brush is essentially a carbon block with a metal spring tail) shows any signs of breakage, crumbling, or burning, the brush needs replacing. Additionally, if you find any abnormal coloration such as rainbow patterns on the spring, if there is a broken lead in the spring, or if the spring has collapsed, your brushes should be replaced. It is also important to note that if a worn brush is used for too long inside your tool’s motor, they can damage or destroy the armature (the commutator bars on the armature that the brushes make contact with) – needless to say, an armature is a much more spendy and complicated repair than is a few carbon brushes.

Ultimately, with poor performance, zero performance, sparking, or bad smells, your tool will show you when its brushes need replacing; it is, however, always better to be safe than sorry, I’d recommend checking-up on your brushes from time to time to ensure you continually reap superior performance and superior results from your power tools.

Click here for a great article on how to replace the brushes in your power tool.

Being green and environmentally/economically responsible isn’t just a fad or trend these days, it’s a bona fide lifestyle that is finding greater popularity as each day rolls on. You see, being green is generally easy, and what’s more, it usually saves you money as well; what could be better than that?

 Well, I’ll tell you – we in the tool industry get to participate in a special kind of green living that keeps a good power tool in our hands, productivity on the agenda, and more dollar bills in our pockets. These green habits for power toolers can be pretty simply summed up in just two magic words: maintenance, and refurbishing.

First and foremost, properly and regularly maintaining your power tools and power tool parts is one of the most important things you can do as a craftsman. It is a widely known fact that a well oiled machine (or at least and clean and cared for machine) will run better and last longer than if simply left to its own devices. This regular maintenance ensures your equipment will perform better under any circumstances and continue performing better for a longer period of time. A colleague of mine can still milk a surprisingly veritable performance from an eighteen year old cordless drill (hey, Jon!); that’s a pretty incredible track record, and certainly one not impossible to replicate, especially if you practice our second bullet point as well: refurbishing. Repairing your power tools rather than replacing them is truly one of the smartest practices to incorporate into your tooling routine. It’s just like that old adage goes – you wouldn’t throw out your automobile for a failing windshield wiper or a balding tire, so why throw out your power tools for a faulty switch or worn-down brushes?

Repairing your power tools can save you an impressive chunk of change, but what’s more, is it will also help you reduce your own carbon footprint. Every power tool that we can keep out of a landfill reduces the units of carbon dioxide emitted into our Earth’s atmosphere. This, consequently, keeps us, our projects, and our big blue Earth safer, healthier, and altogether happier. Reducing our consumption and refurbishing our power tools may seem like just a drop in the ocean, but I promise it will make a difference and soon we craftsman will be making waves with our charm and eco-mindedness. So, my friends and fellows, I appeal to you, repair your power tools, its just plain-old smart.

And, don’t be discouraged at the thought of performing your own repairs, most minor fixes like carbon brush, power cord, or tool housing/clamshell replacements, and many switch replacements as well, can be performed by any old craftsmen. Simply purchase your replacement parts, and should you need an extra hand, a technician, video tutorial, or “how to” article can usually walk you through the process. Other, more complex repairs can be handled at a power tool service center for a fairly menial charge. This is clearly a very small price to pay to revive your power tools, honor thy proverbial mother, and keep some big bucks in your bank account.

Buying used power tools is another way to keep your carbon footprint small and your wallet fat. Used tools can usually do all the same things a brand new one can, but they do them for a fraction of regular cost.

As you can see, green is the new black. Reduce your consumption, reduce your carbon footprint, and benefit from high-performance refurbished power tools and the warm feelings you’ll get for acting smart.

Click here for a step-by-step guide to replacing the brushes in your power tool.

Click here for a step-by-step guide to replacing the switch in your power tool.