Model 5200 High-Level Orderpicker

Section 7.Component Procedures

Electrical Components Motors (General)

Set up and rigidly adhere to a strict inspection schedule to obtain the maximum efficiency from the electrical equipment.

2.Check brush spring tension. See “Motor Brush Spring Tension” on page7-62.

3.Clean brushes and holders. Wipe the commutator with a dry, lint-free cloth. Do not use lubricants of any kind on or around the commutator.

4.Check brush holders for solid connection to the mounting support. Tighten the mounting screws as necessary.

5.Check the cap screws holding the brush cross connectors to the brush holder body.

Each partial inspection of the motor should include the following:

1.Inspect the brushes for wear and for correct contact with the commutator. Record the level of wear on the brushes. This history gives you an indication of whether a brush should be changed or if it can wait until the next inspection. Refer to page7-62 for acceptable brush length and general motor information.

NOTE: Overloading a unit is ultimately reflected in the motor and brush wear; therefore, you must take this into account when considering brush replacement.

6.Make sure the motor terminals are secured tightly to the motor frame. Do not strip the threads or crush the insulating parts. See “Terminal Hardware” on page7-63.

7.Check all the cap screws around the frame for tightness.

8.Keep the outside fram e of the motor clean and free from dirt. Maintain a free air passage around the motor to permit heat radiation.

Replacement

If one brush needs replacement, always replace the entire set of brushes.

Use only genuine Raymond brushes. Using another type of brush could damage the commutator or cause excessive brush wear and voids your warranty.

Publication Number: 1043922B, Revised: 2 Sept 2015 7-61

Section 7.Component Procedures

Model 5200 High-Level Orderpicker Motors (General) Electrical Components

If the end of the brush is not already contoured to fit the commutator, form the brush contour using a brush-seating stone.

Motor Brush Spring Tension Inspection

1.Turn the key switch OFF and disconnect the battery connector.

2.Remove the tractor cover.

3.Slide the brush up slightly in its holder.

4.Insert a paper strip between the brush face and the commutator.

5.Place a small leather loop around the coil spring for the brush. If the brush spring has a loop at the brush, hook the spring scale directly to the spring.

6.Attach a 5 lb. (2.27 kilogram) spring scale to the leather loop.

7.While gently pulling the scale outward, slowly pull the paper strip in the direction that the commutator normally rotates.

8.When the paper strip begins to move freely, the spring scale reads the spring brush tension.

9.Refer to the table below for correct spring tension:

10.Repeat steps 3 through 9 for the remaining brushes.

Polishing the Commutator

NOTE: Wrap the stone with narrow (1/2 to 3/4 inch wide) masking tape in a spiral

Publication Number: 1043922B, Revised: 2 Sept 2015