Typically, a loss of power or decrease in overall performance of our power tools can be defined by a damaged connection between the tool’s power source (i.e., power cord or battery) and the motor of the power tool. the tool. However, right where this fault exists along the electric highway, is where our journey begins. To find our weak link, we’ll simply follow the flow of power from the tool’s power source to the tool’s motor, checking our major components along the way.

Starting with the power cord, just make sure there are no cuts or breaks; this will prevent electricity from fully flowing to the tool and tool motor. If everything looks good with your power cord, our next step is to check your brushes. While the power switch is the first point of arrival for electrical current to the tool, bad brushes are much easier to spot and are also often the culprit of an underperforming power tool, so for now, we’ll skip the switch and move on. in front of the carbon brushes.

If your carbon brushes no longer make full or effective contact with the armature commutator bars, this will cause poorer performance and can also contribute to difficult start-ups. There are a few reasons brushes and commutator “break” in the first place: excessive wear, chipping, or not-so-elastic springs will prevent the brush body carbon block from contacting the commutator. Also, heat damage, which will appear to be melting, burning, or any other form of discoloration, will prevent the brushes from performing to their full capacity. This, of course, decreases the overall performance of the tool. When suffering from any of the above, the brushes should be replaced promptly to prevent further damage to the other components of the tool. The nature of the damage, particularly heat damage, extends to neighboring parts inside your power tool, so if your brushes are badly damaged, I suggest immediately inspecting the armature for signs of similar wear. However, if all looks good in brush territory, you can check your switch.

I say “might” simply because, in general, a bad switch will prevent the tool from starting completely rather than just leaking out of the tool’s power output. However, despite the improbability, it is still possible for heat damage or a badly worn switch to cause decreased performance. Heat damage will appear to be burned, charred, melted, or discolored to the switch body, wires, or wire insulation. Because heat damage may not always be clear, if you know the switch has recently been overloaded or had excessive exposure to moisture, it may be smart to replace the switch anyway.

Also, because I’m pretty sure the problem doesn’t lie with your switch, we’ll continue with the more important components of the tool, armor, and field. I’ll first point out though that if your armor or field is damaged you may also see sparks or smoke coming from the tool; Likewise, if smoke or sparks are coming from your tool, you almost certainly have armor or field damage. However, such damage can still exist without outward signs; but I digress. Now, as you’ll recall, if your brushes are heavily damaged, it’s also a damage indicator on armor which, if left unchecked, will quickly spread damage to the field. First, check the commutator on the armature to make sure the bars form a perfectly even circle. If there are raised spots or indentations on the circle, this will damage the brushes, contribute to weaker or stalled electrical conductivity, and the armature will need to be replaced. Any discoloration on the commutator will indicate heat damage which will also decrease the conductivity and overall performance of the tool.

If the commutators are bad, and especially if they have visible heat damage, it’s important to check the armature assembly as well. Here the heat damage will again be seen as burning/melting/discoloration of the wires or insulation or the assembly itself. Keep in mind that a damaged armature set will actually act like a cancer in your power tool that will quickly spread to the other components and quickly reduce the tool’s function ability.

If any armor damage is found, it is important to also check the field of the tool, which is very close to the heartbeat of our power tools. Although generally durable, if the field sustains any heat damage (from overheating, overloading, misuse, etc.), this will certainly cause a problem, so to speak, in the performance of your tool. As with your armor, heat damage will show up as melting, burning, or discoloration of the field wiring, insulation, or assembly itself. Remember that both the field and the armature are extremely vital parts in your power tool; if they suffer, you and your work will too. Taking your tool and its components for granted is a sure way to end up with an underperforming power tool.

Also remember that damage is like a cancer in your power tools that will continue to spread and get worse if not removed; Replace your damaged parts early to prevent further and more expensive damage in the future. Consequently, if any component, especially the armor, is severely damaged (by heat), it is important to check the other components of the tool as well. Also, if you know the tool has been overloaded, and because these problems can appear in any combination and in any order, it’s always a good idea to check the entire tool for signs of damage.

Essentially, if your tool feels a little sluggish I’d say head straight for the brushes, this is where the weak point in an underperforming power tool tends to be. If after performing an inspection and any necessary replacements, your tool still feels bad, take it to an authorized power tool service center for professional diagnosis. Lastly, always good luck in your power tool endeavors!