Model 5200 High-Level Orderpicker

Section 7.Component Procedures

Electrical Components Motors (General) configuration. Leave only enough stone exposed to make contact with the commutator. As the length of the stone becomes shorter with use, peel back and remove portions of the tape.

Make sure loose clothing and hair are tied back. Do not wear jewelry. Wear insulated gloves to protect your hands during this procedure.

1.If the motor has four or more brushes, remove an accessible brush from the motor with the motor still installed in the truck. If the motor only has 2 brushes or the commutator is not accessible with the stone, the armature must be installed in a lathe or replaced. If so, go to step 4.

2.Activate the motor.

3.With the motor turning, carefully insert the commutator stone into the brush box area.

4.Using minimal pressure, run the stone back and forth across the commutator until it is polished. Do not pass the stone over the ends of the commutator segments.

5.Thoroughly blow out the motor with compressed air.

6.Inspect the commutator. Reinstall the armature or brush and any removed covers.

7.Check operation.

Commutator Inspection

Inspect the commutator for surface condition and high mica.

The commutator must be smooth and clean to provide maximum brush wear. When commutators are not correctly maintained, carbon dust can collect in the grooves between the segments. This can lead to a short circuit in the armature.

Good commutation is indicated by a dark-brown, polished commutator and an evenly polished brush wearing surface.

If the commutator appears rough, pitted, or has signs of burning or heavy arcing between the commutator bars, the motor should be removed for servicing.

Terminal Hardware

Whenever you disconnect and reconnect any power leads to a motor, always tighten the motor cable securing nuts with a torque wrench to prevent over-tightening them and damaging the motor. Use a second wrench on the stud terminal securing nut to avoid twisting the stud. Check these torques each time you check motor brushes. Two different methods are used to connect power leads on this lift truck. The

Publication Number: 1043922B, Revised: 2 Sept 2015

Section 7.Component Procedures

Motors (General)

Model 5200 High-Level Orderpicker