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How to Repair an Electric Motor Controller

Most small appliances and toys get plenty of use, so issues with malfunctioning electric motor controllers are likely at some point in the life of the device. Controllers can turn on motors, manage the speed and, in the case of toy cars or games, establish a direction for movement. A handheld controller, in particular, can be subject to accidental abuse if it's dropped on the ground or intentional damage if it is thrown by a child during a fit. No background in electronics repair is needed to observe and develop simple solutions to get a controller working again.

Things You'll Need

  • Screwdriver
  • Electrical tape
  • Soldering iron
  • Flux-dispensing pen
  • Spray solvent
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Instructions

    • 1

      Open the controller housing with a screwdriver. Most likely, the back of the handheld unit will have two to four small screws keeping the two halves together; the controller for an appliance, such as a washing machine, is accessible behind its cover. Keep all parts removed from the controller, such as the screws, in a safe location to prevent loss.

    • 2

      Examine the wires leading to the on-off switch and any other components controlled by the device. Look for loose or broken wires leading to terminals or at the point of entry into the controller. For example, rough or regular use may cause a wire to become dislodged from a connection, causing complete failure or irregular function.

    • 3

      Determine whether any components have been broken. If the electric motor controller has a circuit board inside, the jarring of resistors or other system components may have broken the solder point keeping them attached to the board.

    • 4

      Repair broken wires by soldering or taping the copper end to its proper terminal. Many simple controllers have a wiring diagram printed inside one half of its plastic case to guide you, if necessary. Use black electrical tape to secure free connections, such as wires attached to a switch, even if the wire can be screwed to the terminal. Solder any loose or broken components directly to the circuit board; use a flux-dispensing pen to control the amount of compound used.

    • 5

      Lubricate a sticky or inoperable metal switch or dial. Spray a small amount of rust-preventing solvent on the metal parts and flip the switch several times or turn the dial.


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