Bulgarian Repair: Diagnostics and Troubleshooting

Corner grinding machines are good and reliable devices in general. They can perform a rather wide range of works. However, their periodic breakdowns are inevitable, any home master must know how they are eliminated.


Before talking about the main failures in the work of the Bulgarian, about the methods of combating them, it is necessary to deal with the design features. Its study is greatly facilitated by the fact that the scheme of electrical and mechanical components in almost all ESMs approximately coincides. Small differences are connected only with proprietary innovative solutions, promoted by individual manufacturers, and with specific devices for individual functions. Almost any modern Bulgarian is equipped with a resistant plastic hull. Usually it is done not monolithic, but broken by 2 components that bind with screws. Where the drive is located, ventilating holes are envisaged. The electromotor itself is formed by the combination of the following elements:

  • rotor;
  • stator;
  • Electric brushes.

When creating a stator, bipolar coils are used to which copper wire is wound. The total number of turns is selected very carefully. Defining it, engineers take into account the desired parameters of the device. Attaching the rotor to the stator occurs due to bearings. The rotor itself is made of electrical steel. It form slits that allow you to place the winding wires. The number of grooves and features of the winding can not be considered trifle: it depends on these parameters, at what speed can OSM can work. The role of brushes – transmission of current between cable and collector.

On this review of the electrical components of the Bulgarian can be completed, but there are also mechanical devices in it. Great value has a gearbox, the body of which is made of durable aluminum-based alloy. It is this material that is selected due to the combination of excellent fortress and high thermal conductivity. The gearbox must allow reliable fixing the elements of the device. It provides holes in which auxiliary handle is mounted. With the help of the gearbox, the force generated by the engine is broadcast. If this node breaks, then the operation of the ABM or becomes impossible at all, or is happening on the “wrong” turnover.

Reducer axis equipped with a pair of bearings. From them, the impulse gets the slave of the planetary type gear. At the end of the shaft, a carving under the nut, clamping edged discs. And on the axis, the anchor will press the sun gear. She is the leading link for the conical gear.

It is still necessary to say about a flatulent coupling – it is extremely important when the disk suddenly gets. If this clutch is not, any jam will lead to the opposite strike, with all its unpleasant consequences. This item is structurally performed in the form of two disks. Normally, they are very tight brought together. The slowdown of the rotary shaft stop allows you to significantly reduce the load arising from such a PE. As a result, the overall resource of the Bulgarian is effective.

Remove and replace the disk on modern ESMs very convenient thanks to a special button. When presseding it, the planetary gear gear is strictly fixed. Fasten grinding circles for normal operation helps nut in the shape of a cylinder. Working with her helps a special key, usually included. To start the engine and smoothly start work, another button is provided. Part of the USM models can also adjust the spindle turnover and prevent overloading.

Diagnostics of faults

How it is not difficult to understand from this description, the device will rather just just in the technical plan. And you can almost always find the cause of problems, without contacting service centers. Start appropriate with the work of the brushes. In the usual situation, they must be spoken, and smoothly and moderately. If the sparks are much or, on the contrary, there is no one, the electrolates must be replaced as soon as possible.

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One of the frequent reasons why Bulgarian does not turn on, is only a rupture of the network cable – along the entire length or input. It is such an assumption worth putting forward, faced with the problem. Before disassembling the mechanism, you need to check the multimeter or a simple indicator screwdriver, is there a voltage. It is recommended to make sure whether there is electricity in the house (apartment). If the voltage is present, but the device does not work anyway, you need to check the electric motor. Its serious faults are the following:

  • short circuit between adjacent turns;
  • breaking individual turns of an anchor or stator;
  • Running collector lamelles.

Problems with an anchor are detected as three characteristic features as:

  • noticeable housing heating;
  • Typical smell of Gary;
  • Strengthening sparks on the collector.

In some cases, to confirm the assumption of problems with anchor, enough external inspection. At the same time it is found that the windings have darkened, and the plates burned or peeled. But it is worth considering that the visual manifestations of the problem are not always found. To determine the real cause of the failure, you will need to check the multimeter. The device is switched to the resistance of 200 Ohm and are consistently evaluated which resistance between couples of adjacent lamellas – in the normal place it must coincide.

But the resistance on the site from the lamellae to the anchor case must have an infinite amount. In stator windings, the conclusions are checked, the resistance between these conclusions and the case is estimated. The standard multimeter does not allow you to find the intercity closures of states and anchors. This task is confidently solved only the devices of a special sample. Sometimes, if the ESM does not start, it’s all about violating the button. When its contacts are covered with dust, they quickly destroy overheating. The test is carried out as in the previous case, a conventional multimeter.

Important! Pretty rarely have to deal with problems of revolt and condenser regulator, overwhelming interference.

As for mechanical deformations, it is mostly necessary to deal with the wear or irrevocable destruction of bearings.

This defect is manifested in the following:

  • increased noise;
  • vibration on the housing;
  • Strong overheating of the surface.

Failures in the work of bearings (wear) can be assumed not only when the hull is heated. Any owner of the ushm knows exactly how intensively the device is used. With a significant, systematically appearing load of the gear or teeth of the gearbox, may well break faster than other parts. It is very important to inspect the problem detail. Then it becomes clear whether it is possible to repair or not.

Pretty many people face a problem when Bulgarian is not gaining momentum, that is, does not develop the full required power. First of all, it is necessary to check in such cases, is the block itself regulating the intensity of the twist. And it should also be estimated to estimate the state of the electrolates and springs of the brush holders. It is impossible to discount the fall of revolutions due to breakage of the feed cable (from frequent bends, from hitting the circle).

To determine whether the quality contact is easy – with its disorders, the insulation of the wire becomes overheated. Of course, it is possible to feel it only after turning off the USM. In order not to spend time on unnecessary checks, you should think that it could cause such a failure. If problems arose after repair, you can assume even errors when reverse assembly. Usually, the disorders in the power supply of the engine or in its windings are accompanied by strong vibrations.

In some cases, the brandy nut is unscrewed. Mostly this trouble occurs on the ESM with a disk from 150 mm and more. Elevated torque increases the probability of tightening nuts to the limit. If the inertial forces are relatively small, such a danger is also less likely. Breakdown of the stopper, as well as the situation when the disk bored, is recognized easily even without special knowledge, so no additional comments require.

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Repair with your own hands

Identify the problems a little – you should also know how to eliminate them. To unscrew the same nut, if the regular key does not help, you need to use the rod. It is inserted into the holes, then try to blow a hammer to move fasteners in the desired side. But it takes it very carefully to avoid breaking the button. Often meet recommendations to warm up the nut itself. The most sparing method implies the climbing of the edges of the disk up to a problematic methization. Next, you will need to choose the following items:

  • relatively thin steel plate;
  • Spare Bulgarian with his disc;
  • Just thin disk.

Damaged disc is stable. But his fixing fasteners break undesirable. The procedure will take a maximum of 5 minutes.

More serious problems are sometimes required to disassemble the Bulgarian. It is worth sticking to the following sequence:

  • Previously, you remove the retaining disk nut;
  • After that, the bolts fixing the protective casing are removed;
  • Following them comes a turn of bolts on the building and in it;
  • Next, remove the top of the back of the case and twisted the bolts that fastening the cord;
  • both cables and buttons must be removed from the grooves; Separate models come with a monolithic rear of the housing, which is only completely removed;

  • Now you can change the engine – first turn off its wires, remove the brushes, and then separated the gearbox from the outer body of the grinder; Without this manipulation, pull the anchor of the electric motor will not work;
  • Further, the device, retracting air and bolts, pressing the stator to the body, as well as the contact springs attached to the stator wires are removed;
  • The stator itself is removed after the cautious blows of the Cyan in the ribs, otherwise it will not move from the spot;
  • The next step in the disassembly – removal of the bolts of the gearbox and extracting it.

Assembly is made in reverse sequence. It must be remembered that the casing of the part of the ESM does not wind up bolts, but snaps up. Its removal is very simple: you only need to turn the cut at an angle of 90 degrees to the tool. Return the casing to the place, turning it back to click.

Can repair the grinder and in more complex cases. For prepared people, even rewinding at home does not represent a special problem. It will only be necessary to prepare enamel and electrical cardboard. The process is made as follows:

  • First, the winding and former isolation is removed from the case;
  • Further, the grooves are examined – if the coils are burning, insulation inevitably turns out to be rooted;
  • part of the material is filmed on the housing – these layers are required to be cleaned with the appropriate or a diamond bora; Leaving them in place, risk damageing a new winding;
  • split wires can only be divided after burning outdoor insulation;
  • Then they measure with a micrometer of any of the wiring, now determine the number of turns is very easy;
  • Next, take any wire from which the loop placed in the stator grooves; According to its diameter, the cylinder is chosen, which will serve as the basis for winding;

  • Enamel pipe coolant;
  • Frontal parts are associated with thick technical threads; It is better to do this with the help of glass beverages, since it definitely does not break down and will not be melted;
  • For the remaining edges, shrinkable cambricks are worn by free edges;
  • Electrotechnical cardboard will make it possible to make sleeves; inserting these sleeves into the grooves, placing windings in them;
  • Next, the resistance is neatly measured by a multimeter;
  • impregnation of varnish will eliminate vibration and mutual friction of wires;
  • Connect devices only after drying varnish.
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Sometimes there is a need to change the direction of rotation of the ESM disk. Normally, he should spin sure that the sparks flew towards working with the tool. Yes, overalls will be faster. However, in the case of PE, the nozzle will fly forward and does not cause harm. Therefore, it is possible to reconfigure the device only if the sparks fly “from the operator”.

Precautionary measures

Using the Bulgarian should be carried out in strict accordance with the instructions and safety requirements. The same rule applies to repair. It is worth adhere to the following precautions:

  • It is also categorically impossible to diagnose, not to mention the replacement of individual parts if the device is connected to the power grid;
  • When removing bearings, take care of a reliable stop;
  • For knocking out parts, only oscillations made of soft metals are used;
  • It is unacceptable to press new bearings with direct hammer blows; You can only beat on the tube, which will push the items to the right position;
  • After dismantling the bearings, they are carefully cleaned, removed lubricant; remove everything, even minor pollution, by washing with alcohol;
  • To exclude errors, after the assembly, you must check whether there is no backlash.

Care and Proper Operation

To preserve the performance of the instrument and their own health, should be used by the Bulgarian only for those for which it is intended. It is worth paying attention to the following rules:

  • You can not use any lubricant, any spare parts except those recommended by the manufacturer;
  • All firms warn in their instructions that it is possible to work with the ears only with well-being; Even ordinary fatigue, not to mention alcohol or narcotic intoxication, is a serious danger;
  • It is impossible to carry out any work if the protective cover is removed;

  • All the time should be controlled by the location of the wire – it should not fall under the cutting or grinding disk;
  • Checking the technical condition of the instrument must be carried out before the start of work, and after its completion; It is advisable to inspect the ESM, after a long (from 1 hour and more) breaks;
  • Regardless of the brand and the model, it is necessary to disassemble the tool from it from time to time, sways from it all the contaminants, updating the lubricant of the running parts;
  • It must be remembered that the Bulgarian is not intended for work and even for storage under high humidity conditions;

  • It is always necessary to put it in such a way that the tool does not fall accidentally, not exposed to the pressure of heavy items; It is worth remembering that the cord should not hang;
  • It is required to minimize the folding and twisting of the cable;
  • It is categorically unacceptable to transfer the grinder for the network wire or tightening it to him;
  • disk and other nozzle pick up strictly under the work that they are going to perform;
  • When cracking, or even single elevation – the circle is subject to immediate replacement; Similarly, it should be done with disks that have the wrong form;

  • When the circle is replaced, it is started for 30 seconds in a trial mode; If during this time there will be no unusual noise, vibrations or beats, everything is in order;
  • It is impossible to leave anything in the working area, which can easily light up, grow hard or explode;
  • It follows only with good lighting on a steady platform (support);
  • You can not keep the processed workpieces in the hands – they are either clamped into vice, or they charge someone to keep the confusion keys.

Important! Compliance with these uncomplicated rules avoids injuries and extend the time of use of the grinder, giving repairs.

About how to repair a grinder with your own hands, look in the following video.

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