Keeping an older machine running

A well-built power tool is meant to be repaired, not thrown away. Brushes, bearings, switches and seals are stocked for machines going back decades, so an older tool that loses power is often one part order away from working properly again. The trick is knowing what to check first.

When a tool loses power

Start with the simple causes before you open the housing. Many complaints about a weak or stuttering machine turn out to have nothing to do with the motor.

• Cable and plug. A damaged cable or a loose plug connection makes the power come and go. Check the full length, especially where the cable enters the tool.
• Accessories. A blunt blade, a worn sanding pad or a blocked extraction hose makes any machine feel weaker.
• Carbon brushes. On brushed motors, worn brushes are a common reason for falling power, heavy sparking or a motor that cuts out. They are wear parts and are designed to be replaced.
• Switch. A switch that has to be pressed several times, or only works in one position, is worn and should be replaced rather than worked around.

Listen and feel

A rough, grinding or rising noise usually points to the bearings. A machine that runs noticeably hotter than it used to, or smells of burning, should be stopped and checked before it is used again. Dust is often part of the story: fine dust that gets into the motor and bearings wears them faster, which is one more reason to run sanders and saws with extraction. Seals keep dust and moisture out of gearboxes and bearings, and a worn seal is often where a bearing failure starts.

Repair or replace

A part order makes sense when the housing, gearbox and motor are sound and the fault is in a wear part. New brushes, a switch, bearings or a seal can bring a good machine back to its original performance, and it keeps working with the accessories you already own.

Replacement makes more sense when the motor winding has failed, when several major components are worn at the same time, or when the work has changed and a newer machine would do it better. Have electrical repairs carried out or checked by a qualified service workshop, and test the tool after any repair before it goes back on site.

Before asking about parts, note the model and serial number from the rating plate. It is the quickest way to get the right part the first time.