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The most common faults of electric angle grinders
Angle grinders are among the most heavily stressed tools, which is why they are more prone to malfunctions.
Common simple faults on angle grinders are easily repairable, and their rectification is not complicated.
Power cable damage
Power cable failure most often manifests at the point of entry into the angle grinder, at the cable grommet, or near the plug. Using an angle grinder with any cable damage is dangerous, as it can result in electric shock.
To fix this fault, the power cable must be replaced. Such a repair should be carried out by a qualified professional (with corresponding electrical engineering education and experience); however, it is ideal to send the tool to an authorized service center. To prevent damage to the power cable, ensure that we do not bend the cable at sharp angles, do not wrap it around the grinder too tightly, and that the conductor is not tensioned during work. Never use the cord for carrying, pushing, or pulling the tool from the mains. Protect the cord from heat, oil, sharp edges, or moving parts.
Fig. 1. Broken cable at the plug
Fig. 2. Broken cable at the entry to the grinder
Wear of carbon brushes
Carbon brushes are an important part of power tools and wear down during operation. Their timely replacement prevents damage to the rotor, the repair of which is more financially demanding.
Two types of carbon brushes are used in power tools, one of which is designated as a "cut-off" brush, and its task is to protect the rotor from damage.
To rectify the fault, the carbon brushes need to be replaced, which we will be happy to help you with in our service center.
Fig. 3. New (1) and worn (2) carbon brushes for the Herman WX 12501 angle grinder
Switch damage
Fig. 4. New switch (1) and damaged switch (2)
The switch is a mechanical, mechanical-electrical, or electronic component. Damage most often occurs due to the accumulation of dust on the contacts when grinding or cutting material. In the worst case, the switch may burn out.
Replacing the switch is not complicated; however, it should be performed by a knowledgeable person, preferably at a service center. If we want to reduce the risk of switch failure, we keep the tool and switch clean and store it in a dry environment.
Faults caused by overloading the angle grinder
More complicated angle grinder faults are caused by long-term overloading of the tool, leading to serious damage to the tool, including destruction of the electric motor, gears, and bearings. Such damage manifests as a change in the tool's speed and sound.
Rotor damage – the rotating part of the electric motor
Rotor failure occurs due to frequent overheating or the entry of processed material particles between the commutator segments. The fault manifests as sparking on the commutator segments.
If the tool continues to be used despite the fault, it leads to the destruction of the rotor, tearing of the commutator segments, or even burning of the windings. Such a fault also affects other parts of the tool, so be sure to contact the service center. You can protect the rotor from damage by replacing carbon brushes in time and not overloading the grinder.
Fig. 5. New rotor (1) and rotor with damaged segments (2)
Stator damage – the static part of the electric motor
Fig. 6. Damaged (burned) stator (1) and new stator (2)
Stator damage is usually caused by rotor overheating, which results in damage to the stator windings.
As with rotor replacement, we recommend using service center services, as this fault is usually accompanied by other malfunctions. We protect the stator from damage by not overloading the grinder.
Gear damage
A symptom of angle grinder gear damage is a change in the tool's sound and increased spindle play.
Further use of such a damaged tool can lead to teeth being torn off the gears or even gear jamming.
To prevent gear damage, we only use accessories suitable for the given type of grinder.
Fig. 7. New gears (1) and damaged gears (2)
Spindle lock damage
Fig. 8. Spindle lock damage: damage to the locking pin housing (1), damaged locking pin (2), new locking pin (3)
Damage to the spindle lock is also a common fault of angle grinders. The lock's task is to fix the disc during loosening or tightening. A frequent cause of its damage is using it to brake the disc, which in the better case causes wear of the lock edge, in a worse case tears the lock out of its housing in the gearbox, and in the worst case breaks a part of the housing.
To rectify this fault, pressing out and pressing in of the gears is required. This task requires special tools, so you will not avoid contacting a service center. To avoid damaging the spindle lock, never use it to brake the grinder.
Marek Baláž
I started working at HERMAN as a service technician in 2013. During this period, I had the opportunity to get to know each tool model down to the last screw, so to speak. Later, I had headed the service department for several years and was personally involved in testing new products. Currently, I am the manager of the production department of abrasive tools. At the moment, I dedicate all my free time to the reconstruction of my family house, where I can use and appreciate the excellent quality of our products in practice.
Csaba Kiss –
Könnyen érthető szakszerű magyarázat.Hasznos volt és érdemes elovasni!
Easy to understand professional explanation. It was useful and worth reading!
Translate text Show originalJakub –
Pre správnosti by sa malo ísť s každým poškodením do servisu ale všetci vieme že každý máme v sebe kúsok šikovnosti tak to skúsime po svojom. Čiže jednoduchý návod ako zistiť príčinu.
To be on the safe side, you should take every damage to a service center, but we all know that we all have a bit of ingenuity in us, so let's try it our own way. So here's a simple guide on how to find the cause.
Translate text Show originalKamil –
Názorný popis a zobrazenie náhr.dielov,len odporúčaniami sa nie vždy riadime
Illustrative description and display of spare parts, we do not always follow recommendations
Translate text Show original