Ametek Motor Lighted Application

Ametek Motor Lighted Application
Increase Quality Through Interaction with the Field
The Oreck Manufacturing Company
Classic & XL21 Upright
Guide 8147
07/19/2004
Compiled by Clark DeNoble
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Increase Quality Through Interaction with the Field
Table of Contents
Upright
Tune Up
Square Heyco Removal
Johnson Motor Wiring
Ametek Motor Wiring
Johnson Motor Brush Replacement
Grip Wiring
Fan/Fan Housing Removal and Installation Methods
Bag Dock Removal and Installation
Microsweep Removal & Replacement
Performing a Cord Cut-Back
Increase Quality Through Interaction with the Field
Pages 3-8
Page 9
Page 10
Page 11
Page 12-13
Pages 14-15
Pages 16-20
Page 22
Page 23
Pages 24-25
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Increase Quality Through Interaction with the Field
Tune-up
1. Turn the unit on and check that the bag inflates, lights work (if equipped) and
brushroll spins. Check 2spd operation (if equipped).
2. Turn off the unit and unplug from outlet. Remove the inner filter bag. Retain
the bag just in case the contents will need to be analyzed.
3. Check for clogs at the connector/deflector opening.
4. Remove dirt tube assembly from the nozzle assembly.
a. Unhook the bag retainer spring from the bag clip.
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Increase Quality Through Interaction with the Field
b. Unfasten the lower collar and slide the dirt tube out of the fan housing’ s
neck. Check for clogs in the dirt tube and fan housing (rolling the brushroll
manually may help the process).
5. Check the baseplate for completeness and damage to components. Remove
the baseplate (5 screws).
6. Remove the drive belt (check that it is an Oreck belt).
Brushroll Pulley
7. Check for clogging at the inlet of the pivot.
8. Check the fan and fan housing for foreign objects. Remove the pivot screw.
Remove the motor screws. Lift the motor and pivot and remove the pivot.
Note: The motor screws are longer than the pivot screw. Don’t mix them up.
Pivot seal
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Increase Quality Through Interaction with the Field
9. Clean the components:
Use the following:
a. WD40: remove marks from cords and bumpers
b. Oreck Spot & Stain and Carpet & Upholstery Shampoo
c. Oreck Glass & Mirror Cleaner
d. Oreck Hospital Clean (Liquid only, not the aerosol)
e. Diluted O'Monster
f. Steam cleaning (Sanapathic with the filtering medium removed from the
filter container) is an effective method of cleaning.
g. Use soap (Joy, Ivory, Dawn) and water as the primary cleaning
ingredients.
10. Cleaning behind brushroll bearings (added 7/19/04): Cleaning behind the
bearing in a labyrinth type bearing protection system is simple using a
homemade tool described below.
Figure A illustrates a wire “floss” used to clean behind the bearing. It is made of
.010” stranded wire with knots tied at about 1” intervals. It is from a purse handle
wire kit found in craft stores. Cost ~$2.00
A
Figures B & C illustrate the two types of bearing protection systems used in our
Classic brushrolls. Figure B is the felt seal and Figure C is the labyrinth (Also
used in the XL21).
B
C
Figure D shows the proper placement of the “floss”. To unwind debris, “floss”
clockwise on the pulley side and counterclockwise on the other side.
D
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Increase Quality Through Interaction with the Field
E
Figure E shows debris displaced by flossing. Pull out debris and repeat flossing
process until no more debris shows.
Citrus-based cleaners (with orange oil) cause plastics to become brittle. Do not
use.
11. Replace the pivot seal.
12. Commutator Polish Method 1:
a. This is the preferred method if you are either unfamiliar with electrical
dangers or just uncomfortable working around live voltage/current.
b. You will need a green scrub pad, 7/16” socket w/extension and battery
operated drill/screw gun.
c. Fit the socket, extension and gun together. Place socket over fan nut.
d. Hold scrub pad onto the commutator with thumb.
e. Operate the gun counterclockwise.
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Increase Quality Through Interaction with the Field
f. Repeat the procedure but use a different green scrub pad to clean the
motor shaft.
g. Install the pivot and motor assemblies and fasten.
h. Skip to step 13.
13. Commutator Polish Method 2: Install the pivot and motor assemblies and
fasten.
a. Clean the motor’s belt drive shaft and commutator. Hazardous
conditions will exist during this step wear safety glasses, remove
jewelry from hands, wrists and neck (if dangling). Secure loose
clothing and long hair.
b. Plug in and turn on the unit.
c. Lightly touch the commutator with the commutator cleaner. Burnishing
will happen quickly. Stop as soon as the carbon is gone.
d. Turn the commutator cleaner over and do the same for the belt drive
shaft.
e. Turn the unit off and unplug from outlet.
14. Install the brushroll and belt.
Incorrect Installation
or
=
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Increase Quality Through Interaction with the Field
Correct Installation
Gap between the belt and washer
Oreck Belt
Aligned on brushroll pulley
15. Replace the baseplate gasket.
16. Reassemble unit and install new filter bag.
The new CC bag may be a
tight fit for some outer
bags. Eventually the
cardboard tab will be
scored so it can be bent
down out of the way.
Non-dock filter bags must
be installed as shown
puffed out. Before the unit
is run the outer bag must
be zipped up. Puffing the
filter bag and supporting it
with a zipped outer bag
will prevent blow off.
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Increase Quality Through Interaction with the Field
Square Heyco Removal
Method 1:
Using a ¼” flathead screwdriver pry up the narrow side first then pry up the wide
side.
Narrow Side
Wide Side
Method 2:
Apply a slight tension on the cord while using a tool, with a 900 bend at the tip, to
loose the grip of the strain relief’s legs. Push in Leg A then Leg B and finally to
pull in Leg C.
Bottom
Leg
A
Leg
C
Top
Leg
B
Leg A
Leg C
Leg B
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Increase Quality Through Interaction with the Field
Johnson Motor Unlighted or Commercial Application
Note the orientation of the
motor bracket
Power Terminal Upper:
White Power Harness Lead
Additionally Power
Terminal locations are
identified with a black dot
Power Terminal Lower:
Black Power harness Lead
Johnson Motor Lighted Application
Black lead from light
harness #1connects
here
White lead w/piggy back
(PB) terminal from light
harness #1 connects here &
the white lead from the
power harness connects to
the PB terminal.
Note: If you don’t have a PB
connection on the harness
you will have to splice the
white light lead to the power
harness white lead.
Black lead from light
harness #2 connects
here
White lead w/piggy back (PB)
terminal from light harness #2
connects here & the black lead
from the power harness
connects to the PB terminal.
Note: If you don’t have a PB
connection on the harness you
will have to splice the white
light lead to the power harness
black lead.
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Increase Quality Through Interaction with the Field
Ametek Motor Unlighted or Commercial Application
Power Terminal Upper:
White Power Harness
Lead
Note the orientation of the
motor bracket
The power terminals
are located closest
to the motor brush
holders
Power Terminal Lower:
Black Power harness Lead
Ametek Motor Lighted Application
White lead w/piggy back
(PB) terminal from light
harness #1 connects here &
the white lead from the
power harness connects to
the PB terminal
Note: If you don’t have a PB
connection on the harness
you will have to splice the
white light lead to the white
power harness lead.
Black lead from light
harness #1 connects here
Black lead from light
harness #2 connects here
White lead w/piggy back
(PB) terminal from light
harness #2 connects here &
the black lead from the
power harness connects to
the PB terminal.
Note: If you don’t have a PB
connection on the harness
you will have to splice the
white light lead to the black
power harness lead.
Removing and Replacing Motor Brushes on the Upright Johnson Motor
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Increase Quality Through Interaction with the Field
Remove the Johnson motor brush by gripping the back end of the old brush
assembly and pulling it out.
Replace the Johnson motor brush by pushing in the new motor brush assembly
and snapping it in place.
With pliers grip the back end of the
assembly and pull it out.
Be sure the locking tabs are on top. Push
the assembly in until it “snaps” in place.
Lighted 1spd - Domestic - Not hardwired
White lead from the receptacle
fitted to the switch and the white
lead from the cord is fitted to the
piggyback terminal.
Note:
The switch terminals are
configured two close together
and one away.
Black lead from
the cord.
Black lead from
the receptacle.
In the picture the white leads
piggy-backed are connected to
the one away terminal and the
black leads are connected to
the terminals that are close to
each other.
The effect of reversing the
white lead piggy-back and the
black lead from the receptacle
is highlighted on page 12.
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Increase Quality Through Interaction with the Field
Lighted Switch Blows Circuit Breakers
Normal Continuity Indications
Neutral blade to neutral receptacle outlet=0
Neutral blade to hot receptacle outlet=OL
Hot blade to neutral receptacle outlet=OL
Hot blade to hot receptacle outlet (switch ON)=0
What was indicated on a nonconforming unit:
Neutral blade to neutral receptacle outlet=0
Hot blade to neutral receptacle outlet=0
(This indicates the hot & neutral were in direct contact)
(This condition will blow circuit breakers all day long)
Neutral blade to hot receptacle outlet=OL
Hot blade to hot receptacle outlet=OL
(This indicates the hot is not connected to the hot outlet)
Reason: Switch installed backwards
Incorrect
Incorrect
Correct
Correct
Note position of terminals:
The neutral terminal should standalone to the rear.
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Increase Quality Through Interaction with the Field
Unlighted 2spd – Domestic - Hardwired
Unlighted – 1spd – Domestic – Hardwired
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Increase Quality Through Interaction with the Field
Lighted – 1spd – Domestic – Hardwired
Unlighted – 1spd – Commercial- Hardwired
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Increase Quality Through Interaction with the Field
Fan/Fan Housing Removal and Installation Methods
1. XL21 (no equivalent step for the Classic fan housing)-Using a flathead
screwdriver with at least a 3/8” blade, POP off the two spring clips holding the
scroll housings together (be sure to POP the spring away from you)(removing the
spring clips quickly reduces damage to the scrolls and the clips. See Figure 1.
Figure 1.
2. XL21 (no equivalent step for the Classic fan housing)-Remove the two scroll
screws and the spring retainer collar screw.
3. XL21 (no equivalent step for the Classic fan housing)-Remove the scroll cover.
4. Classic & XL21-Clamp the belt end of the motor shaft in a bench vise using
two pieces of wood, plastic or aluminum (fabricated as shown below in figures 2
& 3) to prevent damage to the shaft.
5. An alternative that would be helpful for removing the fan but wouldn’t hold the
shaft for removing the nut. Cut slot the size of the motor shaft in a piece of ¾”
thick material. Slide the motor shaft into the slot and then proceed to step 6.
Figure 2 below: Fabricating this block and using it with a bench vise will allow you
to remove and install the fan nut and housing without damaging the motor shaft.
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Increase Quality Through Interaction with the Field
The hole must be a
smaller diameter
than the shaft to get
the holding effect.
Hole formed with
letter N drill bit
(.3020”) then cut
the block in half
through the hole.
Figure 2.
¾” thick block of
nylon or aluminum
Bench Vise
Figure 3.
6. Using a 7/16” socket, turn the fan nut CW to remove (you may need to hold
the fan if the shaft starts turning if using step 5) Figure 4.
Figure 4.
7. Remove the lock washer.
8. Insert a 75377-01 Fan Housing Removal Tool (Figure 5) in the gap between
the scroll/fan housing and the motor bracket (Figure 6) and pry the scroll/fan
housing and fan off the shaft (Figure 7).
Figure 5.
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Increase Quality Through Interaction with the Field
Figure 6.
Figure 7. Push down and up it comes.
This tool was made for the classic. TheXL21 so it will be a tight fit. You need only
to get the tips of the blade inserted for it to work. Beveling the first inch of the
inside edges of the fork may help use on XL21 configurations.
A Simpler Method of Assembling Classic Fan Housings
Fan housing repairs were done with the seal and fan left attached to the motor. A
simpler method, especially with the pressed-in seal, is displayed.
Step 1 - Fan Housing
Step 3 – Gently tap in the seal
Step 2 – Drop in the fan (blades down)
Step 4 – Ensure seal is flush with housing
Step 5 - Install assembly onto motor shaft.
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Increase Quality Through Interaction with the Field
Remove the Seal from the Fan Housing with Minimal Effort
1. Make the punch using an old screwdriver (optional) but the shank helps
stabilize the process
Insert driver
and mark
shank at
indicated
point
Mark handle
end at least
3/8ths inch
from the
housing
surface
Saw the driver at the
two points markedthe punch is ready
2. Make the fixture using ¼” plywood
Cut the two holes as shown then put
the large one on top of the small one
as shown and fasten together
3. If using plywood thicker than ¼” you must cut a relief into the larger hole to
accommodate the neck of the housing
4. Arrange the housing, fixture and punch as shown
We are using a large bench vise because
turning the handle to close the jaws and
press out the seal requires almost no effort.
Remove the Fan Housing Leaving Seal and Fan on Motor
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Increase Quality Through Interaction with the Field
Fan Housing Puller
Fabricate a 1 7/8”x 1” x 1/8” bar with a hole
in the center to accommodate the puller
bolt. In this case we used an eyebolt with
nut. A lock washer was installed between
the nut and bar. Pull on the eyebolt as
you screw it in the lock washer will hold
the nut in place so the bolt could be
driven through the nut.
Slip the bar under the fan housing and
screw in the bolt against the motor shaft
until the assembly pulls apart.
If you use an eyebolt you may need to
insert a screwdriver into the eye for
leverage.
Install New Fan Housing with the Seal and Fan on the Motor
1. Fit the new fan housing to the
seal.
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Increase Quality Through Interaction with the Field
2. Clamp opening should be at least
4” with the clamp screw fully
retracted. Two clamps are needed.
Here we chose to use small bar
clamps.
3. Note the location of the clamp
jaws: at the motor bracket
mounting holes. The motor
bracket is strongest here and can
take the force of the press.
Tighten the clamp screws evenly.
4. Tighten the clamp screws until
the fan housing is hard up against
the motor bracket.
5. Remove the clamps and check
that the seal is seated flush to the
fan housing.
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Increase Quality Through Interaction with the Field
Bag Dock Removal and Installation
1. With the bag dock hinge open, squeeze the bag dock rear.
2. This will release the bag dock hinge. Just let the inner bag & dock hang out of
the way.
3. Pull apart ends to remove bag dock rear from the connector.
4. With outer bag installed, slide the bag dock rear down around the connector.
5. Ensure the bag dock rear is captured behind the tabs on the connector and
reattach the bag dock hinge.
Tabs
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Increase Quality Through Interaction with the Field
Microsweep Removal & Replacement
1. Pull up on the microsweep while gently loosening the
channel’s hold on it. Take care not to pry so hard that the
channel loses tension.
2. Continue removal of the microsweep as shown prying the
channel portion that is free of the microsweep.
3. Slide in the new
microsweep.
5. Sometimes all the
prying slightly
displaces the
channel. Give it a
squeeze to snap it in
place.
4. You may need
to open the gap to
aid installation.
6. Pull all along the
microsweep to assure
it’s locked in place.
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Increase Quality Through Interaction with the Field
Cut-Back (Shown is a commercial hardwire handle but the process is valid for all):
A
1. Open the handle grip.
2. Remove the wire nuts from any connections
already made (A & B).
3. Determine what terminated lead/s will need
to be spliced (S).
S
B
4. The bad spot is usually at the exit point from
the handle grip.
5. Cut the cord about one inch down from the
exit point or bad spot.
Note: If the jacket is frayed it is likely that
the wire conductors have broken or burned
out at the bad spot. Cutting here will save
time.
6. Determine the longest lead length needed and
mark the cord where the jacket should be
removed.
7. Cut the jacket without cutting the wires
underneath and remove.
8. Trim off the filler (string wound up with the
leads).
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Increase Quality Through Interaction with the Field
9. Slide the old jacket off any leads that
will be remaining (send to warranty).
10. Cut back the terminated lead at least
past the bad spot. Leaving too much lead
will just make reassembly difficult.
11. Strip about 3/8th inch from the ends of all leads
that need it.
12. Connect the appropriate wires with
wire nuts.
13. Properly fit the cord and wires into the
handle grip cavity to avoid being pinched during
assembly.
14. Reassemble grip.
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