KOBLENZ P-2500 A (01) PDF MANUAL

A). Set hi-pot meter at 1500 V.

B). Product Switch to on position.

C). Touch one probe of the tester to a blade of the power cord plug and touch the other probe to the handle tube. There should be no breakdown.

Run the machine without brushes (free running) and check the following:

A). There should be no unusual noise or vibration.

B). The carbon brushes spark should be small and uniform.

C). The current shall be no more than 1.5 A.

D). Run the machine with scrubbing brushes on the floor; the current shall be 3.0 A.

1.1. Disconnect the elbow hose connector from the tray assembly.

1.2. Remove the cover by removing four cover screws.

1.3. Pull open the connector on the motor cable.

1.4. Remove the connector support with the connector block.

1.5. Remove gear cover plate screws from both sides along with cover plates and gaskets.

1.6. Remove the four motor cover screws and the motor cover.

1.7. Remove the bearing clamp screws from both sides along with the bearing clamps.

1.8. Remove the carbon brush holder assembly.

1.9. Remove the field support screws and field supports.

1.10. To replace the field, the connector block must be removed. Push the retaining tab of each terminal with a pin and release it by pulling it out.

1.11. The field and armature may now be lifted out for replacement.

2.1. Position the armature in the field so that the armature commutator is on the same side as the field leads.

2.2. Position an armature bearing package on each end of the armature shaft so that the rectangular projection on the seal is facing the armature winding and is between the bearing and armature.

2.3. Position the armature and the field in the motor frame, making sure the leads side of the field are placed close to the bottom windows in the motor frame which are next to the carbon brush holder.

2.4. The armature bearing and seals on the armature are positioned in their respective places in the motor frame, making sure the two straight sides on the boss of the bearings are in the vertical position.

2.5. Hold the field position, replacing the field supports and screws.

2.6. Replace the carbon brush holder and carbon brushes.

2.7. Make sure that armature thrust plates and the armature thrust balls are in position on the ends of the armature shaft.

2.8. Replace armature bearing clamps on top of the armature bearing, with screws.

2.9. Adjust endplay by adding thin plates until there is 0.005″-0.010″ clearance between the armatures thrust plate on the fan end of the unit, measured by a feeler gage.

2.10. Replace the cover plates, gaskets, and screws.

2.11. Place the block in the detent connector and push the connector on the motor cable closed.

2.12. Place the unit into the cover and secure with the four cover screws.

2.13. Reconnect the elbow hose connector into the tray.

3.1. Remove the four cover screws and separate the base plate and motor assembly from the cover.

3.2. Pull open the connector on the motor cable.

3.3. Remove the motor cable bushing with the motor cable.

3.4. Remove the connector support with the connector block; now the motor assembly may be worked on more easily.

3.5. Remove the spindle brush drive pin by driving it out with a cylindrical punch of suitable diameter and remove the pin insulator.

3.6. Remove the spindle cap insulator by pressing the tab and pulling the cap out.

3.7. Remove the caps from the three screw insulators by prying them off with a screwdriver placed opposite the strap tab on the part and remove the three motor frame holding screws.

3.8. Remove the base plate from the motor assembly.

3.9. Remove frame insulators, spindle retainers, and washers.

3.10. Remove the gear case cover plate screws, the cover plates, the cover plate gaskets, and the motor cover; this provides access to gearboxes.

3.11. The gears or spindle may now be removed by lightly tapping the bottom of the spindle.

3.12. Remove the spindle nuts, the gears, and their keys.

3.13. The gearboxes should be cleaned of all foreign material and old grease.

3.14. Inspect the condition of the armature shaft and gears; if they are damaged, replace them.

3.15. The gears may be replaced by aligning the slot in the gear with the slot in the new or old spindle and reinserting the key, making sure the gear shoulder is placed below in contact with the motor frame and the gear is leaning on the nut.

3.16. Position the gear assembled to the spindle in the motor frame and replace the washers, spindle retainer, and frame insulators. The axial play of the spindle should be less than 0.10″.

3.17. The gear boxes should be regreased with the grease provided in the bag together with the gears, making sure all the grease is used, with most of it applied in the contact zone of the gears.

3.18. Reassemble cover plates, cover plate gaskets, motor cover, and screws in the reverse order of disassembly.

3.19. Replace the connector support with the connector block.

3.20. Replace the motor cable bushing and push the connector on the motor cable closed.

3.21. Reassemble the motor assembly to the base plate in reverse order of disassembly, making sure the frame spacers and motor supports are well positioned.

4.1. Follow steps 3.1 to 3.4 from the standard gear replacement procedure.

4.2. Follow step 3.10.

4.3. Follow step 3.12.

4.4. Remove the spindles by lightly tapping the top of the spindle inside the gear case.

4.5. Follow step 3.13.

4.6. Inspect the condition of the armature shaft and gears; if they are damaged, replace them.

4.7. Insert the new spindles from the bottom of the motor frame and replace the gears, aligning the slot in the gear with the slot on the spindle and reinserting the key. Make sure the gear shoulder is placed below in contact with the motor frame, and replace the nut.

4.8. Follow steps 3.17 or 3.20.

4.9. Reassemble the motor assembly on the cover in the reverse order used for disassembly.

5.1. Follow steps 1.1, 1.2, 1.3, 1.4, 1.6, and 1.8 from the field/armature replacement procedure.

5.2. Replace the carbon brushes and reassemble.

6.1. Remove four cover screws and remove the base plate from the cover.

6.2. Pull open the connector on the motor cable.

6.3. Remove the motor cable bushing.

6.4. Remove the switch box retaining screw.

6.5. Remove the switch box from the tube.

6.6. Remove the switch cover screws and open the cover.

6.7. Disconnect the motor cable from the switch by inserting a round needle of 1.5 mm diameter into the switch hole of each wire and pulling out the wire.

7.1. Follow steps 6.4, 6.5, and 6.6 from the motor cable disconnection procedure.

7.2. Disconnect the line cord from the switch by inserting a round pointed needle of 1.5 mm diameter into the switch hole of each wire and pulling out the wire.

7.3. After replacement is accomplished, the line cord must be reassembled in exactly the same manner as it was prior to disassembly.

8.1. Remove the switch box retaining screw.

8.2. Remove the switch box from the handle tube.

8.3. Remove the switch cover screws and open the cover.

8.4. The switch is held in position by the switch box cover and can now be removed.

8.5. Disconnect the switch from the line cord and the motor by inserting a round pointed needle of 1.5 mm diameter into the switch hole of each wire and pulling out the wire. Replace it with a new switch, making sure that wires are replaced in the same position as they were prior to removal.

8.6. Place the switch on the box and replace the cover, the screws, and the knob.

8.7. Reassemble the switch on the box in the handle and secure with the box retaining screw.

9.1. Remove the spindle drive pin by driving it out with a cylindrical punch of suitable diameter and remove the pin insulator.

9.2. Remove the spindle cap insulator by pressing the tab and pulling the cap insulator out.

9.3. Assemble so the spindle insulator is aligned.

9.4. Reassemble the brush drive pin so that it is equally exposed on either side of the spindle insulator.

10.1. Turn the machine with the brush side facing up.

10.2. Insert a pair of brushes on the 8-slot couples.

10.3. Hold the left brush (black couple) and turn the right brush counter-clockwise (C.C.W.) until the couple unscrews and comes out of the spindle.

10.4. Replace the new right couple (yellow) by turning it clockwise (C.W.) on the spindle, while holding the other brush.

10.5. Remove and replace the left couple (black) in a similar way, turning it C.W. to loosen and C.C.W. to tighten.

11.1. Follow steps 1.1, 1.2, 1.3, 3.2, 3.3, 3.5, 3.6, and 3.7 from previous procedures and separate the base plate from the motor frame.

11.2. Remove the screws, the washers, and the tray.

11.3. The base plate may now be replaced.

11.4. To replace the motor frame, follow steps 3.4, 3.9, 3.10, and 3.11.

11.5. Remove four screws and field supports.

11.6. Disconnect field wires from the brush holder support and remove it.

11.7. Remove screws and bearing clamps.

11.8. Remove push plates and thrust balls.

11.9. Remove the field and armature assembly from the motor frame.

11.10. The motor frame may now be replaced.

11.11. For assembly of the base plate or motor frame, the steps are followed in reverse order.

A) Defective Switch. – Solution: Replace switch.

B) Defective power cord. – Solution: Replace power cord.

C) Defective internal wiring. – Solution: Check wire connection at switch, check motor cord, check armature and field and replace armature and/or field.

D) Motor failure. – Solution: Check armature and field and replace armature and/or field.

E) Worn carbon brushes. – Solution: Replace carbon brushes.

A) Dirt build up in motor. – Solution: Blow with clean air.

B) Bad armature. – Solution: Replace armature.

C) Worn carbon brushes. – Solution: Replace carbon brushes.

A) Broken or missing drive pin. – Solution: Replace drive pin.

B) Gear failure. – Solution: Replace gear.

The cause is a worn or broken yoke spring. The solution is to replace the yoke spring.

The cause is a defective spindle cap or brush retainer. The solution is to replace the spindle cap or retainer.

The cause is a defective coupling. The solution is to replace the coupling.

When ordering, do not forget to specify:

✓ PART NUMBER

✓ DESCRIPTION

✓ MODEL NUMBER

NOTE: Drawing numbers are for identification purposes only.