Common Power Tool Repairs You Can Do Yourself

Before You Begin: Safety First

DIY repairs can save money and extend the life of your tools, but safety must always be your priority:

Essential Tools for DIY Repairs

Before attempting any repairs, gather these basic tools:

• Screwdriver set (both Phillips and flathead in various sizes)
• Allen/hex wrench set
• Small needle-nose pliers
• Wire cutters/strippers (for cord repairs)
• Multimeter (for electrical testing)
• Small brush for cleaning
• Compressed air canister
• Contact cleaner spray
• Machine oil or appropriate lubricant

Diagnosing Common Power Tool Problems

Before diving into repairs, it's essential to accurately identify the problem. Here are common symptoms and their likely causes:

Tool Won't Turn On

• Corded tools: Check power source, inspect cord for damage, test switch.
• Cordless tools: Check battery charge, clean battery contacts, inspect switch.

Tool Runs Poorly or Intermittently

• Check for loose connections.
• Inspect for worn carbon brushes.
• Look for dirt or debris causing obstructions.
• Test for switch problems.

Unusual Noises or Vibrations

• Inspect for loose or broken parts.
• Check for worn bearings.
• Look for damaged gears or moving components.

Overheating

• Check for blocked ventilation ports.
• Inspect for excessive dirt buildup.
• Look for signs of motor strain or overloading.

Common DIY Repairs for Power Tools

1. Repairing or Replacing Power Cords

Damaged power cords are one of the most common and fixable issues with corded tools:

For Minor Damage Near the Plug:

1. Cut the cord above the damaged area.
2. Strip the outer insulation back about 2-3 cm, being careful not to damage inner wires.
3. Strip each inner wire about 1 cm.
4. Attach a new plug following the manufacturer's wiring diagram (typically brown to live, blue to neutral, and green/yellow to earth for European plugs).
5. Secure all connections and close the plug housing.

2. Replacing Carbon Brushes

Carbon brushes are wear items that transfer electricity to the rotating armature in the motor. When they wear down, the tool may run poorly or not at all:

1. Locate the brush caps (typically small rectangular or round caps on the motor housing).
2. Remove the caps using a flathead screwdriver or appropriate tool.
3. Carefully remove the old brushes, noting their orientation.
4. Insert new brushes in the same orientation.
5. Replace the caps and tighten securely.

Always use the correct replacement brushes for your specific tool model. Universal brushes may fit but could cause performance issues or damage.

3. Cleaning and Lubricating Moving Parts

Regular cleaning and lubrication can solve many performance issues:

1. Disassemble the tool as much as safely possible according to the manual.
2. Use compressed air to blow out dust and debris.
3. Clean accessible moving parts with a small brush and appropriate cleaner.
4. Apply a small amount of the recommended lubricant to moving parts and bearings.
5. Reassemble carefully, ensuring all fasteners are properly tightened.

4. Fixing Switch Problems

Faulty switches are common failure points in power tools:

For Sticky or Intermittent Switches:

1. Access the switch according to your tool's manual.
2. Spray a small amount of electrical contact cleaner into the switch.
3. Work the switch back and forth multiple times to distribute the cleaner.
4. Allow to dry completely before reassembling and testing.

For Failed Switches:

1. Purchase an exact replacement switch for your model.
2. Take detailed photos of the wiring before disconnecting anything.
3. Carefully disconnect the wires from the old switch.
4. Connect to the new switch in the same configuration.
5. Secure the switch in the housing and reassemble the tool.

5. Battery Pack Rejuvenation

For cordless tools with declining battery performance:

Cleaning Battery Contacts

1. Remove the battery from the tool and charger.
2. Inspect the contacts for corrosion or dirt.
3. Clean contacts with a cotton swab dipped in isopropyl alcohol.
4. Allow to dry completely before reconnecting.

Reset Battery Memory (For Older NiCad Batteries)

1. Fully discharge the battery by running the tool until it stops.
2. Let the battery rest for an hour.
3. Charge completely without interruption.
4. Repeat this cycle 2-3 times.

6. Fixing a Drill Chuck

Wobbly or slipping chucks can be repaired:

For Keyless Chucks

1. Open the chuck fully.
2. Clean the jaws with a brush and compressed air.
3. Apply a tiny amount of dry lubricant (not oil) to the threads.
4. Close and open the chuck several times to distribute the lubricant.

For Loose Chuck Mounting

1. Look for a retaining screw inside the chuck (often left-hand threaded and requires removal of a plug).
2. Tighten this screw securely.
3. If no screw is visible, the chuck may be press-fit and require professional attention.

When to Seek Professional Repair

While many issues can be fixed at home, some problems require professional service:

• Motor Burnout: Characterized by burning smell, smoke, or severe overheating.
• Major Gear Damage: Indicated by grinding sounds or locking up during use.
• Electronic Control Failures: In tools with speed controls, electronic brakes, or smart features.
• Structural Damage: Cracked housings or damage affecting tool alignment.
• Battery Pack Internal Failures: Swollen cells or batteries that won't charge at all.

At PowerFix Sweden, our certified technicians have the expertise and specialized equipment to handle these more complex repairs safely and effectively.

Preventive Maintenance: The Best Repair is Prevention

The most effective repair strategy is preventing problems before they occur:

• Clean tools after each use, especially ventilation openings.
• Store tools in dry, clean environments.
• Follow manufacturer recommendations for lubrication.
• Inspect power cords regularly for damage.
• Don't overload tools beyond their rated capacity.
• Allow tools to cool down during extended use.

Conclusion

DIY repairs can extend the life of your power tools and save money, but always prioritize safety and know your limits. When in doubt, consult with a professional technician rather than risking damage to the tool or injury to yourself.

Remember that quality tools are designed to be serviceable, and many manufacturers provide detailed service manuals for common repairs. By learning these basic repair skills, you'll not only save money but also gain a better understanding of how your tools function—making you a more effective user in the process.