KOBLENZ P-2600 (01) PDF MANUAL

At the completion of any repair, the product should be electrically tested for running and electric strength as follows:

ELECTRIC TEST

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.

RUNNING

RUN THE MACHINE WITHOUT BRUSHES (FREE RUNNING) AND CHECK:

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. Disconnected elbow hose connector (51) from tray assembly (95).

1.2. Remove cover (35) by removing four cover screws (93).

1.3. Pull open the connector on the motor cable (24).

1.4. Remove the connector support (87) with the connector block (75).

1.5. Remove gear cover plate screws (61) from both sides along with cover plates and gaskets (84-85-86).

1.6. Remove the four motor covers screws (61-99) and the motor cover (60).

1.7. Remove the bearing clamp screws (68) from both sides along with the bearing clamps (69).

1.8. Remove the carbon brush holder assembly (62).

1.9. Remove the field support screws (64) and field supports (65-66).

1.10. To replace the field, the connector block (75) must be removed, push the retaining tab of each terminal with a pin and release it by pulling it out.

1.11. The field (67) and armature (63) 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 (70-71-72-74) 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 (63) and the field (67) in the motor frame (88) making sure the leads side of the field (67) are placed close to the bottom windows in the motor frame (88) which are next to the carbon brush holder (62).

2.4. The armature bearing and seals on the armature (63) are positioned in their respective places in the motor frame (88) 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 fields supports (65,66) and screws (64).

2.6. Replace the carbon brush holder (62) 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 (69) on top of the armature bearing, with screws (68).

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 (84-85-86) and (61).

2.11. Place the block (75), in the detent connector (75), and push close the connector on motor cable (24).

2.12. Place the unit into the cover (35) and secure with the four cover screws (93).

2.13. Reconnect the elbow hose connector (51) into the tray (95).

3.1. Remove the four cover screws (93) separate the base plate (92) and motor assembly from cover (35).

3.2. Pull open the connector on motor cable (24).

3.3. Remove the motor cable bushing with the motor cable (25).

3.4. Remove the connector support (87) with connector block (75), now the motor assembly may be worked on more easily.

3.5. Remove the spindle brush drive pin (96D) by driving it out with a cylindrical punch of suitable diameter and remove the pin insulator (96E).

3.6. Remove the spindle cap insulator (96A) pressing the tab (96C) and pulling the cap out.

3.7. Remove the caps from the three screw insulators (94) by prying them off with a screwdriver placed opposite the strap tab on the part and remove the three motor frame holding screws (93).

3.8. Remove the base plate (92) from the motor assembly.

3.9. Remove frame insulators (83), spindle retainers (82) and washers (81).

3.10. Remove the gear case cover plate screws (61), the cover plates and the cover plate gaskets (84-85-86) and the motor cover (60), this provides access to gearboxes.

3.11. The gears (77 or 78) or spindle (79) may now be removed by lightly tapping the bottom of the spindle.

3.12. Remove the spindle nuts (76) the gears (77 or 78) and their keys (80).

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

3.14. Inspect the condition of the armature shaft (63) and gears (77-78), 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 (80) making sure the gear shoulder is placed below in contact with the motor frame and the gear (77 or 78) is leaning on the nut (76).

3.16. Position the gear (77 or 78) assembled to the spindle (79) in the motor frame (88) and replaces the washers (81) spindle retainer (82) and frame insulators (83), 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, the most of it applied in the contact zone of the gears.

3.18. Reassembly cover plates, cover plate gaskets (84-85-86), motor cover (60) and screws (61-92) on reverse order used for disassembly.

3.19. Replace the connector support (87) with the connector block (75).

3.20. Replace the motor cable bushing and push close the connector on motor cable (24).

3.21. Reassemble the motor assembly to the base plate (92) in a reverse order used for disassembly, making sure the frame spacers (83) and motor supports (90) are well positioned.

4.1. Follow steps 3.1 to 3.4.

4.2. Follow steps 3.10.

4.3. Follow 3.12.

4.4. Remove the spindles (102-103) by lightly tapping the top of the spindle inside the gear case.

4.5. Follow steps 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 bottom of motor frame and replace the gears aligning the slot in the gear with the slot on the spindle, and reinserting the key (80) making sure gear shoulder is placed below in contact with the motor frame, and replace the nut (76).

4.8. Follow steps 3.17 or 3.20.

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

5.1. Follow steps 1.1, 1.2, 1.3, 1.4, 1.6, 1.8.

5.2. Replace the carbon brushes and reassemble.

6.1. Remove four cover screws (93) and remove base plate (92) from the cover (35).

6.2. Pull open the connector on motor cable (24).

6.3. Remove the motor cable bushing.

6.4. Remove the switch box retaining screw (6).

6.5. Remove the switch box (5) from tube (2).

6.6. Remove the switch cover screws (4) and open the cover (9).

6.7. Disconnect the motor cable (24) from the switch (8) 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.

7.2. Disconnect the line cord (23) from the switch (8) 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 an accomplished, the line cord (23) must be reassembled in exactly the same manner as it was prior to disassembly.

7.4. Follow steps from reassembly instructions.

8.1. Remove the switch box retaining screw (6).

8.2. Remove switch box (5) from handle tube (2).

8.3. Remove the switch cover screws (4) and open the cover (9).

8.4. The switch (8) is held in position by the switch box cover and can now be removed.

8.5. Disconnect switch (8) from line cord (23) and the motor (24) 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 on the same position as they were prior to removal.

8.6. Place the switch on the box and replace the cover (9), the screws (4) and the knob (11).

8.7. Reassemble the switch on the box in the handle and secure with box retaining screw (6).

9.1. Remove the spindle drive pin (96 D) by driving it out with a cylindrical punch of suitable diameter and remove the pin insulator (96 E).

9.2. Remove the spindle cap insulator (96 A) by pressing the tab (96 C) and pulling the cap insulator out.

9.3. Assemble the spindle insulator (96-E) is aligned.

9.4. Reassemble the brush drive pin so that equal it is exposed on either side of the spindle insulator (96 E).

This procedure is only for models with an 8-slot drive.

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 C.C.W. until the couple unscrews and comes out of the spindle.

10.4. Replace the new right couple (yellow) turning it 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. for loosening and C.C.W. for tightening.

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

11.2. Remove the screws (98), the washers (97) and the tray (95).

11.3. Base plate may now be replaced.

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

11.5. Remove four screws (64) and field supports (65-66).

11.6. Disconnect field wires from brush holder support (62) and remove it.

11.7. Remove screws (68) and bearing clamps (69).

11.8. Remove push plates (73-74) and thrust balls (72).

11.9. Remove the field (67) and armature assembly (63) from the motor frame.

11.10. The motor frame may now be replaced.

11.11. For assembly of base plate (92) or motor frame (88) the steps are followed in reverse order.

When ordering, do not forget to specify:

✓ PART NUMBER

✓ DESCRIPTION

✓ MODEL NUMBER

NOTE: Drawing numbers are for identification purposes only.

V~: 120

A: 4.2

Hz: 50/60