Independent repair of the Bulgarian Sparky

But the Russian craftsman prefers the Sparky Bulgarians not only because of their high operating comforts, but also the ease of repairing the Sparky Bulgarian, the favorable price-quality ratio, the presence of a speed control device, an anti-vibration handle, and an original casing.

Sparky Bulgarians are produced in three classes: small, medium and large. Class is determined by size. In a small class, 15( fifteen) models are produced, the weight of which varies from 1.2 kg to 2.4 kg. The middle class is represented by three models, the weight of which lies in the range 2.5. .. 3.3 kg. In a large class, 10( ten) models are produced, the weight of which reaches 6.3 kg. Awareness of the Bulgarians Sparky gives a bright appearance: a purple body, a bright red or silver color gearbox body.

Features of the design of the Sparky

Sparky features include:

• Multi-function switch, which provides the function of blocking the spontaneous launch of the grinder;
• The case is made with double insulation;
• There is a soft starter, setting and maintaining a constant rotational speed of the rotor;
• The design of the brush holder does not allow to retain dust and wedge the carbon brushes;
• The Bulgarian uses automatically switched off carbon brushes;
• Complete with antivibration handle;
• Application of a protective cover with the ability to quickly install and remove;
• The gear housing is made of a durable, lightweight magnesium alloy;
• A rational ventilation system that improves the cooling process.

Tool for repairing the Bulgarians Sparky

To qualitatively perform the repair of the Sparky grinder of any modification, you can not do without a quality and necessary tool. There are no special requirements for the instrument.

As bearings are used in the Bulgarian Sparky, it is advisable to use pullers to remove them. The Russian craftsman can do without pullers, but do not perform a qualitative repair.

Repair of angle grinders Sparky is conventionally divided into repair of electrical and mechanical parts.

To repair the electrical part you will need a tester. If you have the opportunity to buy or rent a device for determining short-circuited turns, we recommend using a simple probe IR-2.Such a device allows to find an open or short circuit of turns without dismantling of electrical parts. It is indispensable when repairing the rotor, stator bolgarki.

Prepare screwdrivers of various sizes. Do not do without spanners.

The auxiliary materials require lubrication for gears and bearings, rags or wiping material, detergent fluid. At home, it is recommended to use a mixture of kerosene and gasoline.

If you plan on repairing the rotor or stator of the ears, you will need a varnish or paint to impregnate the windings.

Repairs of the Bulgarian must be carried out in a well-lit, well-lit work environment.

Mechanical faults of Bulgarians Sparky

All faults in Bulgarians are divided into mechanical and electrical.

Mechanical faults include:

• Gearbox failure, gear failure;Seizure or destruction of bearings;
• Destruction of the case of a Bulgarian reducer.

Repair of gearbox

Reducer of Bulgarian Sparky is a gear pair, enclosed in a sturdy housing. A different tool is attached to the spindle of the driven gear, allowing you to work with metal, stone, wood.

Most often, the breakdown of the gearbox is associated with the failure of one of the gears. At the pinion the tooth splits or merges, the bearing needle bearing collapses. In addition, a bearing bush or needle bearing breaks down.

The design of the Sparky grinder of different models differs somewhat depending on the power.

The driven gear in the reducers of the Sparky grinder is attached in two ways: pressed or with a keyed connection. Key connection is most often used in low-power Bulgarians Sparky. A small diameter ball is used as a key.

Repair of Sparky grinder reducer provides not only replacement of the failed part, but also a change of lubricant.

In Bulgarians with a power of more than 1000 W, the driven gear is pressed onto the spindle shaft and is removed only with the help of a press. But with a certain skill, this procedure can be performed without using the press. One has only to remember, caution and accuracy - the main factors of success in the performance of this work.

It is not difficult to remove the driven gear. It is necessary to untwist screws of fastening of a cover of the case, to pull out a cover with the built in bearing and a spindle. Pull the spindle shaft out of the bearing. If the driven gear is attached with a key, then before removing the gear, it is necessary to remove the lock ring. In some low-power models, a small-diameter ball is used as a key.

After removing the lock ring, you can carefully remove the key and release the driven gear. Replacement gear is performed when the percentage of wear teeth. And this is determined only by the area of ​​the contact spot of a pair of teeth. The contact spot is the main characteristic of the working capacity of the gear pair.

The driving gear in the Sparky Bulgarians is even easier to shoot. On all Sparky Bulgarians, the drive gears are attached to the rotor shaft with a key and clamped with a nut with a right-hand thread.

To remove the drive gear, the gearbox must be removed from the stator housing. Before you remove the rotor, be sure to remove the carbon brushes that prevent the extraction of the rotor. Coal brushes in the Bulgarian Sparky small capacity can be obtained by removing the cover of the stator housing. To do this, unscrew the screw at the end of the housing handle and pull the cover.

In Sparky Bulgarians of high power, carbon brushes can be removed without dismantling the handle.

How to change gears in a Sparky

reducer To remove the pinion gear, the released rotor must be clamped in the claims, pre-laying the protective gasket. The gasket should be selected from a soft material, so as not to damage the rotor housing.

Using a S = 12 spanner, unscrew the nut securing the drive gear to the rotor by turning the key counterclockwise. If you do not unscrew the nut from the first time, fill the threaded connection with liquid VD-40.Allow the fluid to act for a while, then try to unscrew the fixing nut. As a rule, it turns out.

When the nut is released, it is possible to pull the rotor shaft out of the gearbox housing. The drive pinion is fixed to the shaft of the rotor with a key.

It is enough to remove the lock ring, if it is provided in the design, pull out the key, as the pinion is simply removed from the rotor shaft.

Remember the golden rule. The gears in the gearbox always change in pairs.

By the way, in the Sparks of small and large capacity, it is possible to adjust the gap between the gears in the reducer using special adjusting pads.

How to replace bearings in the

gearbox One of the faults of the Sparky reducer in the Bulgarian is the spindle shaft play. This can occur both in the event of failure of the shaft bearing, and the bearing needle bearing. The appearance of backlash indicates the destruction of the needle bearing in the gear housing. Particularly difficult is the extraction of the outer race of the needle bearing from the socket in the gear housing.

The easiest way is to take the clip from the case with a suitable tap of the appropriate diameter and a screwdriver. Hold the tap in the socket of the screwdriver and try to screw the tap into the bearing ring. When the tap reaches the bottom of the nest, it will begin to lift the clip.

From the spindle shaft bearings are removed using a puller or folk remedies.

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In the Sparky Bulgarians of low power up to 1000 W, a needle bearing type NK0709 is used. In some low-power models, copper-graphite bushings are used.

The Sparky shaft of Sparky Bulgarians up to 1000 W rotates in a 6300-2RS bearing.

Sparky gun reducers over 1000 W use more powerful bearings: a needle bearing type NK-1212, a sliding bearing type 6206-2RS.Sleeves in bullets of high power are not used.

Malfunctions of the electrical part of the Bulgarian Sparky

With proper exploitation of Sparky, the duration of trouble-free operation can be several thousand hours.

Basic rules for trouble-free operation of power tools:

• Timely replacement of carbon brushes;
• Regular grease replacement;
• Preventing the use of the tool at high loads;
• Avoid overheating of the tool;
• Use the instrument for its intended purpose.

Repair of control circuits for Bulgarian Sparky

The control circuits for Bulgarians of different capacities have their own characteristics. In Bulgarians with a power of less than 1000 W, ARV-2114 Defond switches are used, an electronic device for controlling the spindle speed.

Photo of the control circuit diagram

The control circuits of Bulgarians Sparky more than 1000 W are equipped with circuit breakers of type KD10, a condenser, carbon brushes with a contactor, which are part of the brush holder.

Most often, Sparky Bulgarians fail on the electrical side due to a break in the supply cable. This occurs at the cable entry points into the tool and plug.

The second reason for the electrical outlet of the tool, wear or breakage of carbon brushes. Carbon brushes must be changed when the length of the worn brush is not more than 5 mm.

Rotor Repair

Rotor of the Bulgarian Spark is damaged due to overload and overheating, wear or untimely replacement of carbon brushes, the appearance of breakage or short circuit of the windings, the destruction of the collector or the destruction of bearings, resulting in rubbing the rotor against the stator.

The rotor is a complex part, it is difficult to repair without certain skills, skills and equipment. Preferably buy a new rotor or contact the workshop if you see the rotor for the first time. If you want to repair the rotor of the grinder yourself, refer to the materials already posted on the site. But the breakdown of the rotor is not only associated with the failure of its electrical part. More often, the cause of its escape is the destruction or seizure of bearings. On the rotors of Bulgarians Sparky two bearings are installed. One is from the fan side, and the other is from the collector side.

How to replace the bearings on the rotor of the bulb Sparky

On Bulgarians with a power of more than 1000 W, the following bearings are mounted on the rotor.

Bearing near collector type 6000-2ZP63LDS18.

Bearing on the fan side of type 6202 ZTNHP63LDS18.

Bulgars up to 1000 W are equipped with such bearings.

Bearing near manifold type 6262ZP6E LDS18 SKF

Bearing on the fan side of type 6092ZP63LDS18.

The failure of the bearing indicates the difficulty of its scrolling, jamming, changing the color to dark, breaking the bearing race. Bearings are removed using pullers. The operation is not particularly difficult and can be performed by any user.

Stator repair

The stator construction in the Sparky Bulgarians is no different from the stators of other Bulgarians. Repair consists in finding the causes of breakage and rewinding. To determine the open or short circuit of the stator windings, it is preferable to use the tester and the short-circuit detection indicator.

Rewinding the stator is much easier than repairing the rotor and can be performed at home.

The stator repair algorithm is simple and has been repeatedly shown on the pages of our website. In order to rewind the stator on its own, one must not only be able to correctly calculate the number of turns, their winding order, but also be able to properly impregnate the winding with varnish.

The order of disassembly of the Bulgarian Sparky

Regardless of the power of the Bulgarians of the Sparky family, the order of disassembly is almost the same.

Disassembly begins with the dismantling of carbon brushes. They are easy to get when you remove the housing cover or protection on the brush holders.

The whole thing is that to remove the rotor from the stator housing, carbon brushes prevent the extraction of the rotor, rubbing through the lamellas of the collector.

The gear housing and the stator housing are disconnected in the next step. It is only necessary to unscrew the four screws securing the gear housing and the stator housing.

To disassemble the gearbox housing, remove the cover by unscrewing the four screws. The shaft assembly of the driven gear is mounted in the gearbox cover. Disassembly of the shaft assembly of the driven gear we have already considered.

The electrical part is even easier to disassemble, since the number of parts in its composition is even smaller.

Carbon brushes are mounted in brush holders and fixed with special pressure springs. Brushing out the brushes during the repair, remember the places and directions of their installation. Brushes wear out unevenly. And the wear of the brushes is affected by the angle of rotation of the rotor.

The choice of lubricant and the order of its application to the reducer of the Sparky

. Sparky grinder producers recommend using the grease Liver T-0-1,00 kg for lubricating the tool. But it is allowed to use domestic lubricants specially developed for the lubrication of reducers of Bulgarian. Today, the choice of lubricants for Bulgarians is quite wide.

In addition, quality lubrication for the reducer bolgarki can be made at home.

You just need to take as a basis a lubricant that adheres very well to metal surfaces and with it breaks hard at high speeds. Scientifically, the lubrication of the substrate should have increased adhesion.

As a basis that meets the requirements, grease for the joints of cars is best suited. Take the lubricant SHRUS-4 for the basis.
Add it with a syringe lubricant TAD-17 and mix thoroughly until a consistency of thick sour cream. To interfere with lubrication is better with a drill, armed with a self-made mixer.

The gear unit housing must be filled with as much lubricant as it can fit in half the volume of the gear unit.

gearbox Grease is applied after the old grease has been carefully removed. For a thorough and complete removal of the old grease, it is recommended to use a hair dryer, with which the old grease warms up and easily escapes from all hard-to-reach cavities of the

.

• After 700 hours of operation, check the condition of the carbon brushes;
• With any heating of the housing of the grinder, perform maintenance of the tool;
• It is better to change charcoal brushes more often than to buy a new Bulgarian;
• Monitor the condition of the grease and, if the color changes significantly, replace it;
• To reliably switch on the Sparky small grinder, periodically lubricate the switch lever with silicone grease;
• Listen to the sounds of the gearbox( a working machine does not produce any loud noises);
• Check the clearance between the gears more often. When increasing it, use special shims.(There are three of them in the construction of the Bulgarians of the Sparky family);
• Do not skimp on grease or coal brushes, the more often you change the lubricant and install new brushes, the longer it will serve you;
• If a copper-graphite bushing is used as a bearing in the design of your Sparky family in the gearbox, replace it with a needle bearing of the appropriate size.

If you decide to buy a Bulgarian Sparky family, you will get a quality tool that will bring you joy at work, but will create some problems when repairing the

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