What’s wrong with the brushless electric wrench that stops after just one turn?

Overview of Brushless Electric Wrenches

Brushless electric wrenches are known for their efficiency, longer lifespan, and higher performance compared to traditional brushed wrenches. These tools utilize brushless motors, which reduce friction and heat buildup, leading to more efficient energy use and less wear over time. Brushless electric wrenches are popular in industries like automotive repair, construction, and heavy equipment maintenance due to their compact size, high torque, and durability.

Despite their numerous advantages, some users experience problems with their brushless electric wrenches, such as the tool stopping after just one turn. This issue, though not typical of quality products, can be caused by several factors ranging from battery problems to internal malfunctions. Below, we will explore the possible reasons for this problem and how to address it, while also introducing some top brands and models in the brushless electric wrench market.

Possible Causes for Brushless Electric Wrench Stopping After One Turn

1. Battery IssuesThe most common cause of a brushless electric wrench stopping after one turn is a battery-related issue. Brushless motors are highly dependent on the battery’s charge and performance. If the battery is not holding enough charge or is defective, the motor may stop immediately after a single use.
   • Low Battery Charge: If the battery is not fully charged or is running low, it can cause a drop in voltage, leading the wrench to stop prematurely.
   • Battery Degradation: Over time, rechargeable batteries can degrade, losing their capacity to hold charge. This issue is particularly common with lithium-ion batteries used in electric wrenches.
   • Connection Problems: Sometimes, the issue is as simple as a loose or corroded battery connection that interrupts the power supply to the motor.
2. Motor MalfunctionsWhile brushless motors are generally more reliable than brushed motors, they are not immune to faults. A faulty motor can cause the wrench to stop after a single use. Common motor-related issues include:
   • Worn-out components: If the motor’s internal components, such as sensors or windings, are damaged or worn out, the tool might function erratically or stop working altogether.
   • Overheating: Although brushless motors are designed to generate less heat, if the wrench is overloaded or used continuously without breaks, it may overheat and shut off to protect the internal components.
3. Internal Circuit IssuesModern brushless electric wrenches feature sophisticated internal circuits that control the motor’s performance. If there’s a fault in the circuit, it can cause the tool to stop unexpectedly. Some common circuit problems include:
   • Control Board Failure: The control board regulates power delivery to the motor. A malfunction in the circuit board can cause intermittent power delivery, resulting in the wrench stopping after one turn.
   • Faulty Speed Controller: A malfunctioning speed controller may not maintain the proper power level, leading to inconsistent operation.
4. Clutch or Gearbox IssuesIf the wrench has a faulty clutch or gearbox, it may prevent the tool from functioning properly. The clutch is responsible for disengaging the drive when the wrench is not in use, and a damaged clutch could cause the tool to stop after just one turn.
5. Overload or Mechanical JamIf the wrench is being used on a task beyond its capacity, it may automatically shut off to prevent damage to the internal components. Additionally, a mechanical jam (e.g., debris in the motor or gears) can stop the wrench from turning.
6. Environmental FactorsExtreme temperatures, either too hot or too cold, can affect the performance of a brushless electric wrench. Cold temperatures can cause battery issues, while excessive heat can lead to motor malfunctions. If the wrench is being used in an environment with extreme conditions, it may stop functioning properly.

How to Fix or Prevent the Issue

1. Check the BatteryEnsure that the battery is fully charged and free of corrosion. If the battery is old or degraded, replacing it with a new one is often the most effective solution. Regularly charging the battery and avoiding overcharging can also help maintain its longevity.
2. Inspect the MotorIf the motor is overheating or malfunctioning, allow the wrench to cool down before using it again. For motor-related issues, contacting the manufacturer for a replacement or repair might be necessary.
3. Examine the Circuit Board and Speed ControllerInspect the circuit board for any signs of damage, such as burned-out areas or loose connections. If necessary, take the tool to a professional repair service or reach out to the manufacturer for assistance.
4. Check for Mechanical JamsInspect the wrench for any blockages or debris that could be preventing the tool from functioning properly. Clean the wrench regularly to ensure smooth operation.
5. Use the Tool Within Its Rated CapacityAlways use the wrench for tasks within its rated capacity. Overloading the tool can cause it to overheat or malfunction.
6. Store the Wrench ProperlyStore the wrench in a dry, temperature-controlled environment to avoid damage from extreme temperatures. Keeping the wrench clean and well-maintained will extend its lifespan.

Leading Brands and Models of Brushless Electric Wrenches

Now, let’s explore some top-rated brands and models in the brushless electric wrench category. These brands are known for their quality, durability, and performance.

1. Milwaukee M18 FUEL 1/2″ High Torque Impact Wrench (2853-20)Milwaukee is a leader in the power tool industry, and its M18 FUEL 1/2″ High Torque Impact Wrench is a top choice for professionals. This brushless model delivers high torque, up to 1,000 ft-lbs of fastening torque, making it ideal for heavy-duty applications. It features an advanced motor that ensures durability and long-lasting performance.
   • Key Features:
     • Brushless motor for extended life and increased power.
     • Compact design for better maneuverability.
     • REDLINK PLUS intelligence to prevent overheating and overloading.
     • Up to 1,000 ft-lbs of fastening torque.
2. DeWalt 20V MAX XR 1/2” High Torque Impact Wrench (DCF899B)DeWalt is known for producing reliable and powerful tools, and the DCF899B is no exception. This brushless wrench is engineered for heavy-duty fastening and is highly regarded for its balance and power. It’s suitable for a wide range of applications, from automotive repairs to construction projects.
   • Key Features:
     • Brushless motor for enhanced efficiency and runtime.
     • High torque output of 700 ft-lbs for tough tasks.
     • Three-speed settings for greater control.
     • Ergonomic design for comfort during extended use.
3. Makita XWT08Z 18V LXT® Lithium-Ion Brushless Cordless 1/2” Impact WrenchMakita is a well-respected brand in the power tool industry, and its XWT08Z model is an excellent example of their high-performance brushless impact wrenches. This model is designed for maximum torque and minimal downtime, thanks to its durable construction and long-lasting motor.
   • Key Features:
     • Brushless motor for optimal performance and efficiency.
     • Up to 740 ft-lbs of max torque.
     • Variable speed trigger for versatile applications.
     • Built-in LED light for work in low-light conditions.
4. Bosch 18V 1/2-Inch Impact Wrench (IWH181-01)Bosch is known for making compact and powerful tools, and the IWH181-01 is no exception. This 18V brushless impact wrench is designed to offer maximum power while keeping the tool lightweight and ergonomic.
   • Key Features:
     • Brushless motor for longer tool life.
     • High torque of up to 1,600 in-lbs.
     • Lightweight design for user comfort.
     • High-efficiency charging system.
5. Hitachi WR18DBDL2 18V Cordless Impact Wrench KitHitachi (now known as Metabo HPT) has created an efficient and powerful impact wrench with its WR18DBDL2 model. It’s designed for maximum performance and user comfort, making it ideal for both professional and DIY use.
   • Key Features:
     • Brushless motor for longer runtime and durability.
     • Compact design for ease of use in tight spaces.
     • 1,400 in-lbs of torque for heavy-duty applications.
     • Ergonomic grip for comfort during extended use.

Maintenance and Care Tips for Brushless Electric Wrenches

To ensure that your brushless electric wrench continues to perform optimally and avoid the frustrating issue of the wrench stopping after just one turn, regular maintenance and proper care are essential. Here are some key maintenance tips for prolonging the life of your brushless electric wrench:

1. Proper Battery Care
   • Charging: Always use the correct charger for your tool’s battery and avoid overcharging. Most modern battery-powered tools have built-in protection to prevent overcharging, but it’s still a good idea to disconnect the tool from the charger once the battery reaches full charge.
   • Storage: If you’re not using the tool for a while, store the battery in a cool, dry place, ideally at about 50% charge. This will help prevent the battery from degrading prematurely. Avoid leaving the battery in the tool for extended periods.
   • Cleaning Battery Terminals: Periodically check the battery terminals for dirt or corrosion. Clean them with a soft cloth and ensure they are free from debris to maintain good contact.
2. Regularly Clean the Wrench
   • Dust and debris can accumulate in the motor and gearbox of the wrench, potentially causing overheating and malfunctions. After every use, take a few moments to wipe the exterior of the tool and remove any visible dirt or grease.
   • For more thorough cleaning, use compressed air to blow out any debris from the motor housing and other areas of the tool. Make sure to avoid blowing air directly into the battery compartment.
3. Inspect for Wear and Tear
   • Over time, internal components like the motor, clutch, and gears may wear out. If you notice any unusual sounds, vibrations, or performance issues (such as the wrench stopping after a turn), it may indicate internal damage.
   • Check the motor housing for cracks, and inspect the impact mechanism to ensure everything is functioning correctly. If you’re not confident in diagnosing the issue yourself, consult the manufacturer’s repair guide or bring the tool to a professional technician.
4. Lubricate Moving Parts
   • Brushless electric wrenches generally require less lubrication than their brushed counterparts, but it’s still important to lubricate key moving parts, such as the gear mechanism. Regular lubrication helps prevent rust and wear, improving the efficiency of the tool.
   • Use manufacturer-recommended lubricants and apply them to the moving parts as specified in the owner’s manual.
5. Check Torque Settings
   • For those who use adjustable torque settings on their electric wrenches, ensure that the settings are properly calibrated. A wrench that delivers too much or too little torque can cause mechanical damage to both the tool and the fasteners.
   • Regularly verify that the torque settings are correct for the job at hand to avoid straining the tool.

Additional Features to Consider When Buying a Brushless Electric Wrench

When selecting a brushless electric wrench, there are several features that can impact its usability and effectiveness. Here are some of the most important factors to consider:

1. Torque OutputThe maximum torque output is a crucial consideration, particularly if you’ll be working with high-torque fasteners. Look for a wrench that offers ample torque for the types of tasks you’ll be performing. Some models, like the Milwaukee M18 FUEL and DeWalt DCF899B, provide over 1,000 ft-lbs of torque, which is suitable for heavy-duty applications like automotive repair or construction work.
2. Speed ControlMany modern brushless electric wrenches come with variable speed control, allowing you to adjust the speed based on the task at hand. This feature is useful for preventing damage to fasteners and controlling the application of torque more precisely.
3. Ergonomic DesignThe comfort of the tool should not be overlooked. An ergonomic handle and well-balanced design can reduce fatigue during prolonged use. Look for a wrench with a handle that provides a firm, non-slip grip, as well as a design that distributes the tool’s weight evenly for greater control.
4. Compact Size and WeightCompactness and weight are particularly important when working in tight spaces. A smaller, lighter wrench will be easier to maneuver in confined areas, making tasks like engine repairs or installation in cramped environments more manageable.
5. LED Work LightMany brushless electric wrenches, such as the Makita XWT08Z, come with built-in LED work lights. This is a useful feature for working in low-light conditions, as it illuminates the work area and enhances visibility without needing an additional light source.
6. Brushless TechnologyWhile all brushless wrenches offer longer battery life and less maintenance than brushed models, some high-end models include additional technology, like REDLINK PLUS Intelligence (found in Milwaukee’s M18 FUEL line) or XPT Extreme Protection Technology (on Makita tools). These features offer enhanced protection against overheating, overloading, and dust or water damage, which is particularly useful in harsh working conditions.

Conclusion

Brushless electric wrenches are indispensable tools in many industries, providing high efficiency, reduced maintenance needs, and extended service life. However, like any power tool, they are susceptible to certain issues such as the wrench stopping after just one turn, which can usually be traced to battery problems, motor malfunctions, or circuit failures. By following proper maintenance protocols, inspecting your tool regularly, and ensuring that you’re using the wrench within its specified limits, you can minimize the likelihood of such issues.

Choosing a high-quality brushless electric wrench from trusted brands like Milwaukee, DeWalt, Makita, Bosch, and Hitachi can make a significant difference in performance and reliability. These brands offer models with various torque outputs, speeds, and features to suit your specific needs, whether you’re working in the automotive, construction, or DIY sectors.

Ultimately, investing in a reliable brushless electric wrench, maintaining it properly, and using it within its rated capacity will not only ensure that the tool performs optimally but will also increase its lifespan, making it a valuable addition to your toolkit for years to come.