Complete the steps in these sections to install the brushes:
-
Align the first two adapters, one with cross hole threads
and one without
, with the holes on each side of the yoke
. Align the adapters with the mount side facing the center of the yoke.
-
Install the adapters at the first
, fourth
and seventh
set of holes starting from the outside of the yoke.
-
Secure the adapters using NL8 Nordlock washers
and 5/16-18 x 4 in bolts
.
Torque to 220-240 in lbs (25-27.5 Nm).
-
Repeat steps 1 through 3 for the next four adapters on the same side of the yoke.
-
On the opposite side of the yoke, align and attach the adapters facing the opposite direction of the first three adapter pairs.
-
Repeat steps 1 through 5 for the second yoke.
This section explains how to install the holder mounts using the height setter. The height setter verifies that the holder mount and the brush holders are at the correct distance from the collector ring.
Complete the steps in these sections to install the holder mounts:
-
While holding the trigger (A) in its disengaged position, slide the height setter (B) onto the holder mount (C) until the guide boss (D) is bottomed out in the guide slot (E).
-
With the height setter positioned all the way down, release the trigger (A) and allow it to move to the engaged position (F).
-
Ensure the height setter with holder mount (B) is on the mount side of the adapter (G). Place the height setter with holder mount against one of the adapters on the yoke (H). Position so that the height setter rests against the collector ring (I) until both height setter ribs (J) contact the collector ring.
The adapter may need a rotational adjustment. To maximize ring coverage, use the alternate mounting positions on the adapters as needed.
-
Using a 5/32 in Allen wrench, fasten the 1/4-28 button head cap screws (K) and NL6 Nordlock washers (L) to 110-120 in lbs (12-13.5 Nm) of torque.
-
Use the height setter to check that the brush will be properly centered on the ring when the brush holder is installed. Measure the position of the height setter and compare to the position of the original brush.
If necessary, insert or remove washers by the spacers so that the brush holder is properly centered.
-
Pull the trigger
-
Remove the height setter
-
Repeat the steps in the previous sections of this article for any remaining holder mounts.
-
Torque the 5/16 in adapter bolts to 220-240 in lbs (25-27.5 Nm).
-
If the yoke stud nuts are loose, tighten and torque the nuts to the manufacturer’s recommended torque value.
Complete the steps in these sections to install the brushes into the brush holders.
-
Insert a brush spring (A) onto the spring rib (B).
-
Push until the spring hole (C) snaps onto the spring pin (D).
-
Rotate the brush (A) so the terminal ears (B) point down.
-
Insert the brush (A) into the holder (C) until the terminal ears (B) pass the brush spring.
-
Rotate the brush (A) so the terminal ears (B) point up and start to insert the brush into the holder.
-
Insert the brush the rest of the way into the holder until approximately 1/8 in (3.2 mm) extends out of the brush box, (A) .
-
Insert the brush terminal (D) onto the terminal mount rib (E).
-
To prevent brush binding, lead damage, and interference with the handle (A), position the brush leads (B) as shown:
Review these correct/incorrect examples for additional clarification:
Correct
Incorrect
In this correct example the brush shunts are formed straight up so that they will not catch on the box.
Do not position the brush leads as this example shows. In this position the leads will restrict free movement of the brush (hang up).
-
Align the brush holder (A) with the grooves on the side of the holder mount (B) and slide into the holder mount.
These example images provide additional clarification:
-
Rotate and lock the handle (C) into place while applying light pressure toward the collector ring (D).
-
Repeat the procedures in this article for the remaining springs, brushes, and brush holders.
This section provides visual examples of correctly and incorrectly installed brush holders.