service repair manual

1. Service
Manual
SM576
OPI 5B

2. SERVICE MANUAL INDEX
SPECIFICATIONS
ELECTRICAL
SPEEDS
HYDRAULICS
TIRES AND WHEELS
FLUIDS
SCR TRIMPOTS
TORQUE
PLANNED MAINTENANCE 4
ADJUSTMENTS 6
LOAD WHEEL 9
DRIVE TIRE IO
ELECTRIC MOTOR REPAIR
MOTOR SPECIFICATIONS
11
21
EVl OOLX SCR 22
SCHEMATIC 33
TROUBLESHOOTING 34
HANDSET INTRUCTIONS 41
STATUS CODES 46
HYDRAULIC 73
HYDRAULIC TROUBLESHOOTING 82
MAST
JACKING AND HOISTING
TRANSMISSION
88
102
103

3. SPECIFICATIONS
1.0 Electrical, Amp Draws
1.1 Travel, unloaded, 1A speed
Drive motor amps 85 A
Travel, loaded w/3000 lbs., 1A speed
Drive motor amps 95 A
Lifting, unloaded, pump motor amps
2 stage mast
1.2
1.3
1.4
1.5
2.0 Speeds
2.1
2.2
2.3
2.4 Lifting, loaded w/3000 lbs.
1.3.1 slow speed, freelift __
1.3.2 high speed, freelift __
1.3.3 slow speed, staging 165 A
1.3.4 high speed, staging 245 A
Lifting, loaded w/3000 lbs., pump motor amps
2 stage mast
1.4.1 slow speed, freelift
1.4.2 high speed, freelift
1.4.3 slow speed, staging
1.4.4 high speed, staging
Steering, Motor Amps
__
__
280 A
465 A
1.5.7 Parked, not steering 20 A
1.5.2 Steering pump at relief 40 A
Travel, unloaded, 1A speed
Travel, loaded w/3000 lbs., 1A speed
Lifting, unloaded
2.3.1 slow speed, freelift __ 49 fpm
2.3.2 high speed, freelift __ 68 fpm
2.3.3 slow speed, staging 44 fpm 38 fpm
2.3.4 high speed, staging 67 fpm 59 fpm
2.4.1 slow speed, freelift
2.4.2 high speed, freelift
2.4.3 slow speed, staging
2.4.4 high speed, staging
2 stage mast
2 stage mast
__
_-
31 fpm
41 fpm
3 stage mast
150 A
230 A
190 A
295 A
3 stage mast
26O.A
430 A
300 A
505 A
5.1 mph
4.6 mph
3 stage mast
3 stage mast
33 fpm
46 fpm
28 fpm
36 fpm
-l-

4. 2.7 Lowering, unloaded, overall
2.7.1 slow speed
2.7.2 high speed
2.8 Lowering, loaded w/3000 lbs., overall
2.8.1 slow speed
2.8.2. high speed
3.0 Hydraulics
3.1 Capacity of hydraulic reservoir
3.2 Type of fluid
3.3 Lifting relief valve setting
3.4 Steering relief valve setting
3.5 Brake relief valve setting
4.0 Tires and Wheels
4.1 Drive tire
4.2 Drive tire compound
size 6ilw x 5” x lot"
polyurethane
Shore HAN, 88-92
4.3 Load wheels
size 4” x 6”
4.4 Load wheel compound
5.0 Fluids and Lubricants
5.7 Transmission
5.1.1 Type of lubricant
5.1.2 Capacity
5.2 Hydraulics
5.2.1 Type of fluid
5.2.2 Capacity
-2-
30 fw
60 fpm
30 fw
60 fpm
7.0 gal.
Hydo 32
(Sun Vis 832)
2500 psi
+ 100-O psi
850 psi
r_5 psi
180 psi -.
+5psi
durometer
polyurethane
Dylon nBrc
Shore "An 83 durometer
ATF Dexron II
.8 quart
HYDO 32
(SunVis 832)
7.c gal.

5. 6.0 SCR Card Trimpots
6.1 The trimpots on this card cannot be quick turned. They must be
set by using the EV-100 LX Handset.
of this manual.
See electrical section 7.4
Speed Limit
SLl 2.5 mph
sL2 1.0 mph
a3 0 mph
7.0 Torque
7.2 Drive wheel lug bolts 125 ft./lbs.
7.3 Drive axle hub nut 250 ft./lbs.
7.5 General
.'7.51 Roller ring bolts 50 ft./lbs.
7.52 Chain anchor jam nuts 200 ft./lbs.
7.53 Hydraulic cylinder rod nut
7.54 SAE specs
30 ft./lbs.
Lrrlr DF Lub.
t/440 8.00 6.25 S-50 4.17
t/ea to.00 7.16 6-33 4.66
S/16-18 17.00 t3*ao 11.00 8.00
9 16-S 19.00 14.00 12.00 9.00
y8-16 30.00 23.00 8.00 tr.00 -
38-24 35.00 5.00 23.00 17.00
7/16-14 fo.00 35.00 32.00 24.00
7/t6-r0 5.00 4G.ao 36.00 2'7.00
l/2-13 15.00 5.00 50.00 3s.00
t/2-20 go.00 65.00 55.00 90.00
98-11 tfo.00tto.00 100.00' 75.00
5/a-ta 180.00 tja.oo 110.60 85.00 L
l UUply by (0.1383)far metic &io
-3-

6. 1.0 LUBRICATION CHART
Description Work Directions Materials
1 Load Wheel Axle Use Lubi Gun & Adapter for
flush type fittings Tex. Ref. C & C #880
2 Sheave Pin Use Lub. Gun Tex. Ref. C & C #880
3 Battery Roller Bearings
(optional) Remove, Clean and Repack Tex. Ref. C & C #880
4 Lift Chain Check for Rusting, and Clean SAE 40 Motor Oil
5 Hydraulic Oil Filter Change Oil Filter Filter Element
6 Gear Case -
Transmission I‘Drain, Flush and Refill * IATF Dexron II
7 Hydraulic Reservoir Drain, Fjush and Refill SAE lo-30W Oil
8 Hydraulic Reservoir
Outlet Screens Clean in solvent Solven’t
9 Side Guide Rollers Use Lub Gun & Adapter for
(optional) flush tyde fittings Tex. Ref. C & C #880
10 Sheave Pin on Free
Lift Cylinder - Three
Stage Mast. Only Use Lub. Gun Tex. Ref. C & C #880
After any major disassembly and/or repair the following lubricant should be performed.
Transmission Pivot Brg. Repack Bearing Tex. Ref. c & C #880
Transmission Roller Brg’s. Repack Bearings Tex. Ref. C & C #880
Steering Wheel Shaft Reoil Light Weight Oil
Steering Chain Clean and Reoil / Heavy Weight Oil
Lift Chain Clean and Reoil SAE 40 grade Motor oil

7. DATE
PLANNED
MAINTENANCE
SCilEDiLE
l&w Serial No.
2.0 100 Hour or Monthly PM
I.,Cheok machine operation; all funotiona and safety 8WitOhe8
24 Clean with OOUIpre888d air
;:
Cheok level of hydraulio oil
Servioe all urease fittings, inoluding side auide rollers
i:
Check transmission lubrioant fluid level
Inspeot all tires and wheels
76 Clean and lubrioate lift Ohain8 _
84 Cheok lift ohain adjustment
-9, Inepeot and adjust steering oontrol oable
1Ob Cheok brake adjustment and stopping diatanoe
rl. Inapeot fitting8 and valves for leaks
12. Inspeot for loose & missing part8
13.
i4,
Inspeot wiring
Inapeot oontaotor tips for pitting
15* Lubrioate door hinges
3.0 500 Hour or Semi-Annual PM
.I, Change hydraulio oil filter
21 Clean and lubrioate battery rollers
34 Clean battery and maohine
4.0 1000 Hour or Annual PM
!I Steamolean maohine
24 Drain, flush, and refill gear ease
34 Drain, flush, and refill hydraulio reservoir
ilb Clean hydraulio reservoir outlet so&ens
5* Check hydraulio pressure relief settings
61 lnspeot oondition of lift ohains
7e Inepeot motors; brushes (length) b oommutator
8, Cheek mast and carriage .: lube, adjust, and shim as needed
Orease, lube points and battery pivot
roller8 i Texas IW. C&C#OS0 heavy
Lubrioation Speoifioation
point8 and lift ohaina -
weight oil
Ja Fe Ma
l-l-
I I
I I
Transmission - ATF Dexron II
Hydraulio reservoir - SAE 1OW(IS0 32)

8. Adjustments
1.0 Brake
. The brake release cylinder should have 318" to 112" of travel. The
cylinder travel itself is non-adjustableand the only brake adjust-
ment is the agressivenessadjusting'screwson the side cover of the
transmissioncase. Three allen head screws at the top of the
transmissionside cover adjust braking agressiveness.
Loosen the locknuts and turn all three screws out of the transmission
case until no force is felt pushing against any screw. Turn the screws
back into the transmissioncase just until spring resistanceis felt.
Now turn each screw an additional tw turn and tighten lock nut.
Test braking action.
3.0 Brake Interlock Switch
Make any required brake adjustment prior to this adjustment.
Leave the brake pedal up.
Loosen the switch on the bracket and slide the switch towards
the cam arm until it clicks and then slide approximatelyl/32"
further.
Tighten the switch.
Test the switch by stepping on the brake pedal. The switch
should activate with approximately l/32" movement of the brake
rod.
5.0 Steering
steering is cable and chain operated and power assisted
through the use of a hydraulic torque generator. Because of the
complexityof the steering linkage, if any adjustmentsare required,
the
5.1
entire adjusting procedure must be followed.
5.2
5.3
Adjust transmissionsteering ring guide rollers snug, but not
tight, against the guide ring.
Guide rollers are mounted on eccentric pins. Loosen bolts and
turn cam on eccentric. Be sure to tighten nuts or bolts.
Adjust steering chain around transmissionand bottom sprocket of
torque generator.
Loosen two 3/8" NC bolts that lock chain ends to transmission
case. Turn adjusting turn buckle to tighten chain so that it
has l/8" to l/4" of slack. Tighten locking bolts.
Adjust upper chain around torque generator and jackshaft.
Jackshaft mounting bracket is on a pivot. Loosen locknutson
stud and pivot mounting bracket to adjust chain for l/8" to l/4"
of slack. Tighten lock nuts.
-6-

9. 6.0
11.0
12.0
18.0
5.4 Adjust steering cable in mast.
Raise carriage so that cable tensioner springs and turn buckles
are visible. Roth turn buckles must be adjusted an equal amount
so that the steering remains centered.
Adjust turn buckles so that tensioner springs are collapsed all
but one full coil.
Lift
6.1
Chains
Three
6.11
Stage
Stage cylinder chains
The chains should be adjusted until the tops of the mast
channels are flush within 318”. The chains should be equal
tension.
6.12 Free lift chains.
The chains should be adjusted until the platform is 1"
from the straddle arms.
6.2 Two Stage LFL
The chains should be adjusted until the platfhrm is 1" from the
straddle arms.
6.3 Two Stage FFL
The chains should be adjusted until the platform is 1" from the
straddle arms.
Speed limiting switch
Loosen switch on the bracket and slide switch toward lug on inner
channel until it clicks, then slide approximately l/32" further.
SCR Card Trimpots
See Electrical Section 7.4 of this manual. Handset must be used.
Gate
18.1
18.2
18.3
switch
Remove panel from rear of operator platform.
Place gate in lower position.
Loosen switch on the bracket and slide toward the cam until it
clicks, then slide approximately l/32" further.
-7-

10. 5.4 Adjust steering cable in mast.
6.0
11.0
12.0
18.0
19.0
Raise carriage so that cable tensioner springs and turn buckles
are visible. Roth turn buckles must be adjusted an equal amount
so that the steering remains centered.
Adjust turn buckles so that tensioner springs are collapsed all
but one full coil.
Lift Chains
6.1 Three Stage
6.11 Stage cylinder chains
The chains should be adjusted until the tops of the mast
channels are flush within 318”. The chains should be equal
tension.
6.12 Free lift chains.
The chains should be adjusted until the platform is 1"
from the straddle arms.
6.2 Two Stage LFL
i-.
_
The chains should be adjusted until the platform is 1" from the
straddle arms.
6.3 Two Stage FFL
The chains should be adjusted until the platform is 1" from the
straddle arms.
Speed limiting switch
Loosen switch on the bracket and slide switch toward lug on inner
channel until it clicks, then slide approximatelyl/32" further.
SCR Card Trimpots
See Electrical Section 7.4 of this manual. Handset must be used.
Gate
18.1
18.2
18.3
switch
Remove panel from rear of operator platform.
Place gate in lower position.
Loosen switch on the bracket and slide toward the cam until it
clicks, then slide approximately l/32" further.
Potentiometer
19.1 Connect VOM to wire #29 and wire P13 of the potentiometer.
19.2 Loosen mounting screws rotation to the highest reading on the
VOM.
-8-

11. LOAD WHEEL REPLACEMENT
The load wheels are mounted on an axle bolt and held in place with a nut on
the end of the axle. Roll pins driven into the wheel box side wall through
slots in the bolt head and nut prevent loosening of the axle. The axle
mounts from the outside and the nut is on the inside of the outrigger.
Disassembly:
Raise load wheels off ground and block up safely.
Drive the roll pin that locks the nut in place further into the inside rail
of the outrigger to allow nut to be removed.
Remove axle nut and'remove axle bolt. Load wheels will be free to come
out.
Drive roll pin out of hole on inside rail.
Assembly:
Press bearing cups into load wheels. Place bearing cones and Nilos rings
into wheel. "NilosH ring is%o be installed with the lip facing into the
bearing.
Put wheel and bearings into place in outrigger. Install axle bolt from
outside. Install axle nut from inside. Tighten axle ut only until all end
play is removed from wheel bearings. Turn nut to closest slot that lines
up with roll pin hole. Install roll pin to lock nut in place.
-9-

12. DRIVE TIRE REPLACEMENT
1. Park machine on l:vel floor, lower forks, disconnectbattery and
block machine in both directions at the load wheel.
2. Hoist or jack rear of machine so that drive tire clears the floor.
39 Remove lugs from the wheel studs and remove tire and wheel assembly.
4. Press on new tire, make sure the tire is flush with the lug nut side
of the wheel.
5. Install wheel and lug nuts. Torque lug nuts to 125 ft. lbs.
-lO-

13. 1.0 PRESTOLITE MOTOR SERVICE
INSTRUCTIONS
(General Notes)
CLEANING
Prior to any testing or inspection, the
motor components, except bearings and
armature, should be thoroughly cleaned
with a good grade petroleum base
cleaning solvent and dried with
compressed air.
AWARNING Be extremely careful when
- working with solvent. Even a
small explosion or fire could
cause injury or death.
a
WARNING Wear eye protection and be
- sure to comply with OSHA or
other maximum air pressure
requirements. !
The armature should be blowu’ol’f with
compressed air to remove brush dust and
dirt from around the commutator and
windings.
Bearings should be wiped clean with a
cloth and never submerged in a solvent.
Submerging bearings in a solvent will
deteriorate internal lubrication which
cannot be replaced.
VISUAL INSPECTION
After the motor components have been
thoroughly cleaned and dried, they
should be inspected for the following:
1.
2.
3.
Drive end head
Check bearings recess for any signs
of wear. Check mounting holes for
any stripped or crossed threads or
broken studs.
Commutator end head After thorough inspection, the frame
Check bearing recess for any signs and field assembly should be checked
of wear. Check bearing holder for grounded, open, or shorted cir-
insulation for cracks or any signs cuits. Grounded and open circuits can
of burning. Check brush holders be checked using 110 volt A.C. test
and springs for wear. leads with a 50 watt bulb in series.
Oil seal
Oil seal, if upon disassembly of
the motor, the field coils 0; cum-
mutator are oily. A faulty oil seal
is indicated. A good service prac-
tice is to replace the oil seal
4.
5.
6.
whenever the motor is overhauled.
The oil seal seat on the armature
shaft shouId be checked for rough
spots, grooves, or scars.
Bearings
Check bearings by turning them with
your fingers. Feel for binding or
gritty effects and for excessive
looseness or wobble. A good bearing
should also have a small amount of
drag or stiffness caused by the
lubrication. If the bearing turns
very freely, it should be replaced.
Frame and field assembly
Check the condition of all insula-
tion. If the insulation on the
field coils appears blackened or
charred, the serviceability of the
coils is questionable. Burned or
charred insulation is a result of
coils over-heating due to
overloading conditions,. grounded or
shorted coil windings. Check con-
dition of all other insulation such
as brush rigging, under coil con-
nections, and around terminal
studs.
Armature
Check the shaft bearing journals,
-
splines or keyways for wear. Check
windings, commutator connections
and commutator bars for any signs
of burning. If deep burned sections
are evident, either in the brush
track or on the rider end of the
commutator bars, an open circuit
in the armature winding is indi-
cated.
TESTING
Frame and Field Assembly
1. Grounded circuit
Touch one test lead to a clean bare
metal spot on the frame and check
all terminals with the other lead.
If a grounding condition exists,
the test light lights.
-11

14. 2. Open circuit
Check between all connecting ter-
minals with test leads. If the bulb
fails to light, ari open circuit is
indicated.
3. Shorted circuit
Shorted windings in series coils
are very difficult to detect.
Generally, if the coil insulation
is sound there are no signs of
overheating, the coil can be pre-
sumed good. The individual pages in
your Prestolite service manual
lists the series winding
resistance. The resistance of the
series coils is usually so low a
special ohmeter or ohmeter attach-
ment is needed to check it.
Shunt coils can ‘be tested with an
ohmeter for proper resistance or
with a battery, of the specified
voltage, for proper current draw.
NOTE: The resistance in shunt
field coils may cause the
test light to be dimly lit.
ARMATURE
Check the armature for grounded cir-
cuits by placing one test lead of the
110 volt A.C. test lamp on the com-
mutator and the other test lead on the
armature shaft. If the test light
lights, the armature is grounded.
There are two different electrically
connected types of armatures used in
motors. Each type requires a different
method of testing for shorted circuits.
The individual pages in your Presolite
Service Manual specify the type of
armature used in that particular motor
series.
NOTE: If the armature has been turned
and undercut prior to testing,
check for and remove any copper
buildup or filings between com-
mutator bars and the commutator
riser. This condition will cause
an armature to check shorted and
usually results from a dull
undercutting tool.
1. Standard winding connections
These armatures are tested on a
growler using a steel strip or
hacksaw blade to locate any shorted
windings. Rotate the armature in
the growler while holding the strip
or blade over the armature so that
it passes over each armature core
slot.
If a winding is shorted, the strip
or blade will vibrate.
2. Equalizer winding connections
This tvne of armature cannot be
tested- on a growler like the stan-
dard winding connection armatures.
The equalizer connections are made
between commutator bars .snd will
cause the armature to test shorted.
The only practical method of
testing these armatures is to per-
form a light load test after the
motor has been completely
assembled. 1; the motor does not
meet or exceed all parts of the
light load specification, replace
the armature.
FRAME AND FIELD SERVICE NOTES
If the inside of the motor is excep-
tionally dirty and there is evidence of
a grounding condition caused by dirt,
the inside of the motor can be given an
additional cast of insulating varnish.
Red glyptol can be used if- a better
material is not available, however, we
recommend using a Class “Fw
Polyurethane air drying insulating var-
nish. This is readily available under
various brand names from electrical
repair or parts houses in aerosal type
dispensers.
Before spraying field coils, make sure
they are absolutely clean and dry. Keep
varnish off of brush rigging, pole shoe
faces, and end head seats.
FIELD COIL INSTALLATION
Good solder connections are important
due to the vibration characteristics
encountered by these motors which can
cause cold or poorly soldered eonnec-
tions to break. Prior to installing the
field coils, the connections which
-12-

15. require soldering should be buffed or
wire brushed clean to remove any oxidi-
zation. The connections should then be
tinned with a 90% tin solder using a
soldering iron.
NOTE: We do not recommend using a
soldering gun or torch.
Soldering guns cannot provide
the heat concentration required
and soldering torches can damage
the insulation.
After field coil installation, connect
the solder joint, making sure the
solder is flowing properly to avoid a
cold soldered joint.
There is an optional method of eon-
netting field coils which provides a
mechanical connection prior to
soldering. This method facilitates
soldering and results in a stronger
connection for added vibration protection.
.:_
After tinning and installing the field
coils in the frame, align the coil
straps and drill an 11/64” hole (#18
Drill) thru both straps. Insert a #8-32
brass screw and nut or a brass pop
rivet and solder the connection. After
the connection has been made, check the
clearance between it and the end head
to prevent grounding the connection
when the end head is installed.
ASSEMBLY AND TESTING
After the motor components have been
thoroughly cleaned, tested, and
repaired or replaced, assemble the
unit. Refer to the individual motor
page of your Prestolite Service Manual
for specific assembly information.
After assembly, the motor should be
connected as specified in test connec-
tions, and tested to the specifications
contained on the Presolite service
individual motor page.
Some motors are tested at a voltage
different from the specified or routed
voltage of the motor. This is done to
avoid excessive current draw and, or
excessive free running R .P .M.
ELECTRIC MOTOR REPAIR
SERVICE PROCEDURES
The service procedures are basically
the same for all motors regardless of
size.
DISASSEMBLY
1. Remove the cover band from the com-
mutator end of the motor (if
equipped >.
Cover Band
2. Use a brush hook to reach into the
motor and lift the brush springs.
Pull the brushes out of the brush
holders. Either position the
brushes outside the motor or remove
the brush retaining screws and
remove the brushes from the motor.
Cbmmutatorend head
retaining screws
Brush retaining
screws
When testing motors, the voltmeter con-
nections must be made at the motor ter-
minals.
-13-

16. 3. Scribe or center punch locating
marks in the end head and the
frame. Although locating marks are
not always necessary because of
locating pins in some motors, they
can save a lot of time when the
motor does not have locating pins.
4. Remove the commutator end head
retaining screws. Almost all motors
have a slip fit bearing at the com-
mutator end, and the end head can
be removed with very little
trouble.
On motors that have a shaft exten-
sion on both ends of the armature,
the attachment on the commutator
end of the shaft must be removed
before the end head can be
separated from the motor.
5. Remove the drive end head retaining
screws, if necessary. Some of the
smaller pump motors retain the
drive end head with the motor
through bolts. Separate the arma-
ture and drive end head as an
assembly from the frame and field
coil assembly.
When a puller is used, protect the
end of the armature shaft with a
nut or a thick flat washer. If the
shaft, coupling, or spline is
damaged when removing the end head,
the armature or the drive spline
usually has to be replaced. Use
caution and do not damage the arma-
ture.
7. Separate the bearing from the end
head. On larger motors, the bearing
is retained with a snap ring.
Remove the snap ring. Then’ press
the bearing out of the end head.
End head
/
Drive end head
retaining screws ap ring
Frame and field coil
assembly
Aramature and Bearing Inner Race
Press Ram
size as
drive end head
assembly
6. Separate the armature from the
drive end head. This operation is
usually done by pressing the arma-
ture out of the drive end bearing.
On some of the larger motors, the
end head and bearing will have to
be removed with a puller.
PRESSING END HEAD BACK
ON ARMATURE SHAFT
-14-
End head
Inner
Snap
shaft
Race
Ring

17. 8. The ventilating fans are cast alu-
minum . Once these fans have been
pressed onto the armature, they
must be heated to be removed
without damage.
A puller is installed and a slight
pressure exerted against the fan.
Use a small propane torch to heat
the area of the fan around the
shaft. When the fan becomes loose
on the shaft, as evidenced by the
puller becoming loose, it should be
removed as quickly as possible.
9. When the fan is reassembled on the
shaft, make sure it is a tight fit.
Use “Loctite Retaining Compound 40”
or equivalent on the inside of the
fan hub when reassembling fan.
Use ‘-lo&e*’ on
this area of shaft
10. After the motor has been separated
into all its major subassemblies,
the components should be cleaned
and inspected for wear or damage.
-15-
CLEANING
Prior to any testing or inspection, the
motor components, except bearings and
armature, should be throughly cleaned
with a good grade petroleum base
cleaning solvent and dried with
compressed air.
aWARNING
aWARNING
Be extremely careful when
working with solvent. Even a
small explosion or fire could
cause injury or death.
Wear eye protection and be
sure to comply with OSHA or
other maximum air pressure
requirements.
The armature should be blown off with
compressed air to remove the brush dust
and dirt from around the commutator and
windings.
Bearing should be wiped-.clean with a
cloth and never submerged in a solvent.
SubmergingXings in a solvent will
deteriorate internal lubrication which
cannot be replaced.
VISUAL INSPECTION
After the motor components have been
thoroughly cleaned and dried, they
should be inspected for the following:
1.
3
d.
3.
Drive end head
Check bearing recess for any signs
of wear. Check mounting holes for
any stripped or crossed threads or
broken studs.
Commutator end head
Check bearing recess for any signs
of wear. Check bearing holder %ISU-
lation for cracks or any signs of
burning. Check brush holders and
springs for wear.
Oil seal
-_
If upcn disassembly of the motor,
the field coils or cummutator are
oily. A faulty oil seal is indi-
cated. A good service practice is
to replace the oil seal whenever
the motor is overhauled. The oil
seal seat on the armature shaft
should be checked for rough spots,
grooves, or scars.

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19. 4. Bearings
Check bearings by turning them with
your fingers. Feel for binding or
gritty effects and for excessive
looseness or wobble. A good bearing
should also have a small amount of
drag or stiffness caused by the
lubrication. If the bearing turns
very freely, it should be replaced.
Ball bearings that have been pulled
off of shafts, pressed out of end
head, or side loaded in such a way
as to apply pressure on the balls
and races must be replaced.
Although the bearing may appear to
feel good, the bearing races have
been brinelled and will fail within
a relatively short period of ser-
vice.
5. Frame and field assembly
Check the condition of m insula-
tion. If the insulation on the
field coils appears blackened or ..
charred, the serviceability of the
coils is questionable. Burned or
charred insulation is a result of
coils over-heating due to
overloading conditions, grounded or
shorted coil windings. Check con-
dition of all other insulation such
as brush rigging, under coil con-
nections, and around terminal
studs.
6. Armature
Check the shaft bearing journals,
splines or keyways for wear. Check
windings, commutator connections
and commutator bars for any signs
of burning. If deep burned sections
are evident, either in the brush
track or on the rider end of the
commutator bars, an open circuit
in the armature winding is indi-.
bated.
Loose commutator bars will usually
be indicated by excessive wear or
burning on one bar. The commutator
can be checked for loose bars by
lightly tapping all of the bars
with the handle of a plastic or
wooden handle screwdriver. A
contrasting dulI thud or vibration
will indicate a loose bar in which
case the armature must be replaced.
Place the armature in lathe and
clean the 3ommutator with #000 or
finer sandpaper to determine
whether or not the commutator needs
resurfacing. Light pitting and
wear can be removed with the sand-
paper. Excessive pitting and wear
will have to be removed by turning
and undercutting the commutator.
-16-

20. MOTOR TROUBLESHOOTING
SYMPTOM POSSIBLE CA USE
1. Blows circuit breaker
and shaft turns very
hard
Bad Bearing
2. Blows circuit breaker Shorted armature coil
. 3. Blows circuit breaker
and armature roasted
Check for machine overload
4. Does not run Worn brushes or brush hung
UP
5. Does not run or runs
fast
Open armature connection
6. Motor runs in wrong
direction
Reverse motor connections
REMARKS
Replace bearing
(also check
armature )
Replace armature
Replace armature
and possibly
rear end bell
assembly
Replace or release
brushes and check
commutator
Replace armature
Correct connections
-17-