27
3.
Smooth out minor nicks, burrs, or galled spots on shafts,
bores, pins, or bushings.
4.
Examine all gear teeth carefully, and remove nicks or burrs.
5.
Polish the edges of all shafts shoulders to remove small
nicks which may have been caused during handling.
6.
Remove all nicks and burrs caused by lockwashers.
7.
Replace all seals, ‘O’ Rings and gaskets.
Replace any electrical components that have tested bad or are
burnt. Check all bearings for smooth operation, and replace as
necessary. Inspect gears and gear teeth for burrs, chips, cracks or
missing teeth. For burrs use a hone or fine emery cloth and
remove. When honing gear teeth make sure gear is thoroughly
clean before reassembly to prevent metal particle contamination.
For chipped or missing teeth, replace.
Control Housing Assembly
1.
Apply a small amount of gasket sealant to motor stator
(28), just to hold gasket (24) in place. Attach new gasket
(24) to stator (28).
2.
Place screw (17) through washer (16) and insert it into
relay box (18). Ensure motor wires (U1, V, and W) are
pushed through opening in relay box (18). Mount to stator
(28) and tighten. When looking at the relay box opening on
the stator, the longest part of the stator should be on the
left.
3.
Take screw (81) washer (16) and insert it into ground
(earth) wire eye and fasten to ground (earth) connection in
stator (28).
4.
Push motor wires (U1, V, and W) through hole in control
assembly (5) mounting plate.
5.
Push control cables back through the cable connectors
(19 and 22).
6.
Using screws (4) fasten control assembly (5) mounting
plate to relay box (18).
7.
Using a small, narrow bladed screwdriver (refer to Dwg.
MHP0795) connect the appropriate wires to terminal strip,
refer to wiring diagrams.
8.
Insert screws (2) through cover (1) and gasket (3) and
fasten into relay box (18), tighten.
Trolley Motor Assembly
1.
Place motor cover (27) over (longest) end of stator (28)
loosely.
2.
Insert screws (26) and washers (34) into motor cover (27).
Twist until screws (26) are aligned with holes in stator (28)
and tighten.
3.
Press bearing (30) on short end of rotor (31) and bearing
(32) on long end. Slide into stator (28). Install retainer ring
(29) after rotor shaft protrudes from motor cover (27).
4.
Insert retainer ring (36) into gear housing (33). Place this
assembly loosely over rotor (31) and on stator (28). Install
capscrews (35) and lockwashers (34) through gear housing
(33) and into stator (28). Use a polyurethane hammer to
lightly tap gear housing (33) down until capscrews (35) can
be fastened. Capscrews will pull gear housing (33) down
tight, seating the bearings.
5.
Assemble the following gear components. Pinion shaft
(46), retainer ring (44), bearing (32), key (45), gear (39)
and bearing (37).
6.
Apply a thick coat of gear lubricant to bearing (37), refer to
“LUBRICATION” section. Insert this assembly into the
opening in gear housing (33) and seat with polyurethane
hammer. Fill the rest of the housing with the same
lubricant.
7.
Apply a bead of Loctite
®
515 to surface of gear housing
(33).
8.
Place retainer ring (36) into cover (40).
9.
Insert capscrews (42) and lockwashers (34) into cover (40),
place this over dowels (38) in gear housing (33) and tap
down. Use capscrews (42) to fully seat and tighten gear
cover (40).
Trolley Assembly
1.
Insert capscrews (49) with lockwashers (50) through gear
cover (40) and into trolley side plate (52) and tighten.
2.
Slide spacer (65), washer (64) and same number of washers
(63), as was taken off during disassembly, onto shaft (105).
3.
Insert this assembly into side plate (52). Place the
remaining washers (63) on the shaft (105).
4.
Thread nut (48) onto shaft (105) also locknut (47).
5.
Place counterweight (62) onto side plate (59).
6.
Install capscrews (57) and lockwashers (58) through side
plate (59) and into counterweight (62) and tighten.
7.
Install retainer ring (56) into back of wheel (54) followed
by bearing (55), then install second retainer ring (56). Press
bearing and wheel assembly onto axle taking care to apply
pressure to inter race of bearing only.
8.
Place spacer (65), washer (64) plus the same number of
washers (63) as were used in step 2 on the other side of
shaft (105).
9.
Position both side plates on the beam. Place the rest of
washers (63) on the shaft (105). Thread nut (48) on shaft
(105) followed by locknut (47).
10. Tighten both nuts (48) equally and then tighten locknut
(47). Refer to Table 4 Nut Torque in “INSTALLATION”
section for specifications.
Brake Assembly (optional feature)
1.
Position solenoid (85) in housing (90). Insert capscrews
(86) with lockwashers (16) into access holes in bottom of
housing through solenoid and fasten.
2.
Replace plug (94) in bottom left (as you look at brake)
hole.
3.
Push control cable through other access hole and connect
wires to terminal block (89). Insert screw (81) into
lockwasher (16), ground tab and eye of ground (earth) wire,
into housing (90) and tighten. Maintain a little slack in
wires and route around springs. Fasten cable connector
(95).
4.
Place key (93) in rotor shaft (31) slide brake hub (92) onto
rotor shaft (31) and secure with retainer ring (29).
5.
Insert brake discs (starting with 77 then 76, repeat until all
discs are inserted), brake washer (75) and cup disc (74).
6.
Place spring (98, not available separately, part of 85) on
screw section of solenoid (85). Place spring (87) and spring
guide (88) into slot in housing (90).
7.
Place brake lever (82) into lever block (80) and press down.
While pressing brake lever (82), slide pin (83) through
lever block (80) and brake lever (82) until pin protrudes
through other side. Press on retainer (84). Thread locknut
(97, not available separately, part of 85) onto threaded shaft
of solenoid (85) until 2 to 3 threads are exposed beyond
locknut (97).
8.
Check to ensure that wires are not interfering with spring (87).
9.
Adjust air gap “S” as described in “Brake Adjustment
Procedures”.
10. Insert capscrews (71) with lockwashers (16) through
bottom holes in brake cover (72). Locate gasket (73) on
capscrews and place this assembly onto brake housing (90).
Make sure that control cable wires are not pinched by
capscrews. Tighten a couple of turns.
11. Insert capscrews (70) with lockwashers (16) through top
holes in cover (72), screw into housing (90) and tighten.
12. Tighten capscrews (71).