Beruflich Dokumente
Kultur Dokumente
REF 7901151
PARTS DIVISION
Les pièces de rechange, mentionnées dans cette liste, sont normalement livrables du stock.
En plus, les articles non-indiqués peuvent être fournis en peu de temps. Cette liste peut être modifée
sans avis préalable. Les références O.E.M. sont seulement indicatives et n'impliquent pas que les pièces
de rechange viennent du constructeur de chariots élévateurs.
Toutes les photographies, illustrations, marques, descriptions, tous les plans et numéros servent exclu-
sivement à une identification.
Die in dieser Liste aufgeführten Teile sind normalerweise aus dem Lager lieferbar. Wir sind zudem in der
Lage nicht aufgeführte Teile innerhalb kürzester Zeit zu liefern. Die O.E.M. Referenznummern dienen zur
Information und beinhalten nicht, dass diese vom genannten Gabelstaplerhersteller kommen. Diese
Bestandsliste kann ohne vorhergehende Ankündigung geändert werden. Alle verwendeten Foto's,
Zeichnungen, Abbildungen, Markennamen, Beschreibungen und Nummern dienen nur zu
Identifikationszwecken.
The spare parts mentioned in this list can normally be delivered from stock. In addition, we can supply
parts, which are not mentioned in this catalogue, with the shortest possible delivery time.
The O.E.M. references are only for indication purposes and do not imply that the spare parts are coming
from the forklift manufacturer. This spare parts list can be modified without prior notice. All photographs,
drawings, illustrations, brand names, descriptions and numbers are included for identification purposes
only.
I pezzi di ricambio, menzionati in questo listino, possono essere forniti di consegna immediata a condi-
zione che non sono esauriti. Pezzi di ricambio non menzionati possono essere forniti in poco tempo. Le
referenze O.E.M. sono solamente indicative e non implicano che i pezzi di ricambio vengono di questo
costruttore di carrelli elevatori. Questa lista ricambi può essere agguistata senza avisi anticipati. Tutti i
numeri, codici, nomi, foto, spaccati e disegni sono solo a titolo informativo.
Normalmente tenemos en almacén las piezas de recambio mencionadas en esta lista microfichera.
Tenemos la posibilidad de suministrar las piezas de recambio no mencionadas. Los números de referen-
cia O.E.M. sirven solamente como indicación y no impliquen que vienen del constructor de las carretillas
elevadores. La lista de almacén puede ser adaptada sin aviso anterior. Todas las fotos, despieces, nom-
bres de marca, descripciones y números sólo sirven para identificación.
INDEX page
1
BRUSHES
For all our latest catalogue updates and company info: www.tvh.be
INDEX page
LUGLI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .196
MANITOU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .197
MATRAL (Cfr STILL)
MIC (Cfr JUNGHEINRICH-STEINBOCK)
MITSUBISHI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .199
NICHIYU-NYK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .205
NISSAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .207
O&K ........................... . . . . . . . . . . . . . . . .215
OMG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .216
PEG (Cfr FENWICK & PEG)
PIMESPO (Cfr FIAT-OM PIMESPO)
PATRIA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .217
PRAMAC (LIFTER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .218
PRAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .219
RANSOMES (Cfr HYSTER)
RAYMOND (Cfr BT)
ROCLA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .222
SAMSUNG (Cfr CLARK-SAMSUNG)
SALEV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .224
SAXBY (Cfr STILL)
SHINKO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .225
SICHELSMIDT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .226
SISU (Cfr KALMAR LMV)
STEINBOCK (Cfr JUNGHEINRICH-STEINBOCK)
STILL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .227
SUMITOMO (Cfr YALE)
STOCKA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .245
TCM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .246
TECNOCAR (Cfr BALKANCAR)
TOYOTA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .254
UNITRAC (Cfr CLAAS-UNITRAC)
VALMET (Cfr KALMAR LMV)
WAGNER (Cfr STILL)
YALE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .268
2
BRUSHES
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Part: 1
BRUSHES & BRUSH KITS
3
BRUSHES
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Technische fiche
KOOLBORSTEL
02-12-06-00 gegevens klant:
voorbeeld
CODE: TY x MD x D x B x H x Kw
...,. D . . . . . . . . .Dikte
...,. B . . . . . . . . .Breedte
...,. H . . . . . . . . .Hoogte
..... Kw . . . . . . . .Kwaliteit
TYPES
Enkele kool
Type E1 Type E2
Type E3 Type E4
Meerdere kolen
Type M2 Type M3
5
BRUSHES
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Type M4
AFMETINGEN
meldingsdraad
6
BRUSHES
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Fiche technique
BALAI
02-12-06-00 nom de votre société:
exemple
CODE: TY x MD x D x B x H x Kw
...,. D . . . . . . . . .Epaisseur
...,. B . . . . . . . . .Largeur
...,. H . . . . . . . . .Hauteur
...,. KW . . . . . . . .Qualité
TYPES
Balai unique
Type E1 Type E2
Type E3 Type E4
Plusieurs balais
Type M2 Type M3
8
BRUSHES
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Type M4
4 balais unis
DIMENSIONS
9
BRUSHES
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Technical detail
CARBON BRUSH
02-12-06-00 customer details:
example
CODE: TY x MD x D x B x H x Kw
...,. D . . . . . . . . .Thickness
...,. B . . . . . . . . .Width
...,. H . . . . . . . . .Height
..... Kw . . . . . . . .Quality
TYPES
Single brush
Type E1 Type E2
Type E3 Type E4
Multiple brushes
Type M2 Type M3
11
BRUSHES
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Type M4
DIMENSIONS
Indicator wire
12
BRUSHES
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Technische Daten
KOHLEBÜRSTE
02-12-06-00 Daten Kunde:
Beispiel
KODE: TY x MD x D x B x H x Kw
...,. D . . . . . . . . .Dicke
...,. B . . . . . . . . .Breite
...,. H . . . . . . . . .Höhe
..... Kw . . . . . . . .Qualität
TYPEN
Einzelne Kohle
Typ E1 Typ E2
Typ E3 Typ E4
Mehrere Kohlen
Typ M2 Typ M3
14
BRUSHES
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Typ M4
4 verbundene Kohlenblöckchen
ABMESSUNGEN
Signalkabel
15
BRUSH KITS
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Technische fiche
KIT KOOLBORSTELS DC-MOTOR
02-12-07-00 gegevens klant:
voorbeeld
...,. D . . . . . . . .Dikte
...,. B . . . . . . . .Breedte
...,. H . . . . . . . .Hoogte
..... Kw . . . . . . .Kwaliteit
AFMETINGEN
AT-KO
AT-KB
meldingsdraad
17
BRUSH KITS
For all our latest catalogue updates and company info: www.tvh.be
Fiche technique
JEU DE BALAIS MOTEUR ÉLECTRIQUE
02-12-07-00 nom de votre société:
exemple
...,. D . . . . . . . .Epaisseur
...,. B . . . . . . . .Largeur
...,. H . . . . . . . .Hauteur
..... Kw . . . . . . .Qualité
DIMENSIONS
AT-KO
AT-KB
19
BRUSH KITS
For all our latest catalogue updates and company info: www.tvh.be
Technical detail
CARBON BRUSH KIT DC-MOTOR
02-12-07-00 customer details:
example
...,. D . . . . . . . .Thickness
...,. B . . . . . . . .Width
...,. H . . . . . . . .Height
..... Kw . . . . . . .Quality
DIMENSIONS
AT-KO
AT-KB
Indicator wire
21
BRUSH KITS
For all our latest catalogue updates and company info: www.tvh.be
Technische Daten
KOHLENSATZ - DC-MOTOR
02-12-07-00 Daten Kunde:
Beispiel
...,. D . . . . . . . .Dicke
...,. B . . . . . . . .Breite
...,. H . . . . . . . .Höhe
..... Kw . . . . . . .Qualität
ABMESSUNGEN
AT-KO
AT-KB
Signalkabel
23
BRUSHES
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REF 122TA3898
Should you come across brushes with identical dimensions, and you are not sure what the difference is, please contact us.
26
BRUSH KITS
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Should you come across brushes with identical dimensions, and you are not sure what the difference is, please contact us.
28
BRUSHES
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Should you come across brushes with identical dimensions, and you are not sure what the difference is, please contact us.
29
BRUSH KITS
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Should you come across brushes with identical dimensions, and you are not sure what the difference is, please contact us.
32
BRUSHES
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Should you come across brushes with identical dimensions, and you are not sure what the difference is, please contact us.
33
BRUSH KITS
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REF 121TA2223
Should you come across brushes with identical dimensions, and you are not sure what the difference is, please contact us.
34
BRUSHES
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REF 122TA3912
Should you come across brushes with identical dimensions, and you are not sure what the difference is, please contact us.
35
BRUSHES
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Should you come across brushes with identical dimensions, and you are not sure what the difference is, please contact us.
36
BRUSHES
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used for: BT
used for: BT
used for: BT
used for: BT
Should you come across brushes with identical dimensions, and you are not sure what the difference is, please contact us.
40
BRUSH KITS
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used for: BT
used for: BT
used for: BT
used for: BT
REF 121TA2252
Should you come across brushes with identical dimensions, and you are not sure what the difference is, please contact us.
44
BRUSHES
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Should you come across brushes with identical dimensions, and you are not sure what the difference is, please contact us.
50
BRUSH KITS
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Should you come across brushes with identical dimensions, and you are not sure what the difference is, please contact us.
55
BRUSHES
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REF 122TA4021
Should you come across brushes with identical dimensions, and you are not sure what the difference is, please contact us.
56
BRUSHES
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Should you come across brushes with identical dimensions, and you are not sure what the difference is, please contact us.
64
BRUSH KITS
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REF 121TA2361
Should you come across brushes with identical dimensions, and you are not sure what the difference is, please contact us.
74
BRUSHES
For all our latest catalogue updates and company info: www.tvh.be
REF 122TA4151
Should you come across brushes with identical dimensions, and you are not sure what the difference is, please contact us.
78
BRUSH KITS
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Should you come across brushes with identical dimensions, and you are not sure what the difference is, please contact us.
79
BRUSHES
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REF 122TA4178
Should you come across brushes with identical dimensions, and you are not sure what the difference is, please contact us.
82
BRUSH KITS
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REF 121TA2395
Should you come across brushes with identical dimensions, and you are not sure what the difference is, please contact us.
86
BRUSHES
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Should you come across brushes with identical dimensions, and you are not sure what the difference is, please contact us.
87
BRUSH KITS
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REF 121TA2397
Should you come across brushes with identical dimensions, and you are not sure what the difference is, please contact us.
88
BRUSH KITS
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REF 121TA2398
Should you come across brushes with identical dimensions, and you are not sure what the difference is, please contact us.
89
BRUSHES
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Should you come across brushes with identical dimensions, and you are not sure what the difference is, please contact us.
92
BRUSH KITS
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Should you come across brushes with identical dimensions, and you are not sure what the difference is, please contact us.
99
BRUSH KITS
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REF 121TA2472
Should you come across brushes with identical dimensions, and you are not sure what the difference is, please contact us.
104
BRUSHES
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Should you come across brushes with identical dimensions, and you are not sure what the difference is, please contact us.
105
BRUSH KITS
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REF 121TA2473
Should you come across brushes with identical dimensions, and you are not sure what the difference is, please contact us.
106
BRUSHES
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Should you come across brushes with identical dimensions, and you are not sure what the difference is, please contact us.
107
BRUSHES
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REF 122TA4323
Should you come across brushes with identical dimensions, and you are not sure what the difference is, please contact us.
118
BRUSHES
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REF 122TA4327
Should you come across brushes with identical dimensions, and you are not sure what the difference is, please contact us.
119
BRUSH KITS
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REF 121TA2506
Should you come across brushes with identical dimensions, and you are not sure what the difference is, please contact us.
120
BRUSHES
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REF 122TA6048
Should you come across brushes with identical dimensions, and you are not sure what the difference is, please contact us.
132
BRUSH KITS
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REF 121TA2599
Should you come across brushes with identical dimensions, and you are not sure what the difference is, please contact us.
144
BRUSHES
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REF 121TA2604
Should you come across brushes with identical dimensions, and you are not sure what the difference is, please contact us.
146
BRUSHES
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Should you come across brushes with identical dimensions, and you are not sure what the difference is, please contact us.
159
BRUSH KITS
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REF 121TA2673
Should you come across brushes with identical dimensions, and you are not sure what the difference is, please contact us.
168
BRUSHES
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REF 122TA6056
Should you come across brushes with identical dimensions, and you are not sure what the difference is, please contact us.
180
BRUSH KITS
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Should you come across brushes with identical dimensions, and you are not sure what the difference is, please contact us.
193
BRUSH KITS
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REF 121TA2779
Should you come across brushes with identical dimensions, and you are not sure what the difference is, please contact us.
195
BRUSHES
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Should you come across brushes with identical dimensions, and you are not sure what the difference is, please contact us.
196
BRUSHES
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REF 122TA4759
Should you come across brushes with identical dimensions, and you are not sure what the difference is, please contact us.
197
BRUSH KITS
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REF 121TA2783
Should you come across brushes with identical dimensions, and you are not sure what the difference is, please contact us.
198
BRUSHES
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Should you come across brushes with identical dimensions, and you are not sure what the difference is, please contact us.
202
BRUSH KITS
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Should you come across brushes with identical dimensions, and you are not sure what the difference is, please contact us.
204
BRUSHES
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Should you come across brushes with identical dimensions, and you are not sure what the difference is, please contact us.
206
BRUSHES
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Should you come across brushes with identical dimensions, and you are not sure what the difference is, please contact us.
213
BRUSH KITS
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Should you come across brushes with identical dimensions, and you are not sure what the difference is, please contact us.
214
BRUSHES
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REF 122TA4902
Should you come across brushes with identical dimensions, and you are not sure what the difference is, please contact us.
215
BRUSHES
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Should you come across brushes with identical dimensions, and you are not sure what the difference is, please contact us.
216
BRUSHES
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REF 122TA4905
Should you come across brushes with identical dimensions, and you are not sure what the difference is, please contact us.
217
BRUSH KITS
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Should you come across brushes with identical dimensions, and you are not sure what the difference is, please contact us.
219
BRUSH KITS
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REF 121TA2818
Should you come across brushes with identical dimensions, and you are not sure what the difference is, please contact us.
221
BRUSHES
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REF 121TA2825
Should you come across brushes with identical dimensions, and you are not sure what the difference is, please contact us.
223
BRUSHES
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REF 122TA4922
Should you come across brushes with identical dimensions, and you are not sure what the difference is, please contact us.
224
BRUSHES
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REF 122TA4932
Should you come across brushes with identical dimensions, and you are not sure what the difference is, please contact us.
225
BRUSHES
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REF 122TA4939
Should you come across brushes with identical dimensions, and you are not sure what the difference is, please contact us.
226
BRUSHES
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Should you come across brushes with identical dimensions, and you are not sure what the difference is, please contact us.
236
BRUSH KITS
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REF 121TA2882
Should you come across brushes with identical dimensions, and you are not sure what the difference is, please contact us.
244
BRUSHES
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Should you come across brushes with identical dimensions, and you are not sure what the difference is, please contact us.
245
BRUSHES
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Should you come across brushes with identical dimensions, and you are not sure what the difference is, please contact us.
252
BRUSH KITS
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REF 121TA2885
Should you come across brushes with identical dimensions, and you are not sure what the difference is, please contact us.
253
BRUSHES
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REF 122TA5211
Should you come across brushes with identical dimensions, and you are not sure what the difference is, please contact us.
260
BRUSH KITS
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Should you come across brushes with identical dimensions, and you are not sure what the difference is, please contact us.
267
BRUSHES
For all our latest catalogue updates and company info: www.tvh.be
REF 121TA2990
Should you come across brushes with identical dimensions, and you are not sure what the difference is, please contact us.
281
BRUSHES
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Part: 2
BRUSHES
283
BRUSHES
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complete range
Should you come across brushes with identical dimensions, and you are not sure what the difference is, please contact us.
284
BRUSHES
For all our latest catalogue updates and company info: www.tvh.be
complete range
Should you come across brushes with identical dimensions, and you are not sure what the difference is, please contact us.
285
BRUSHES
For all our latest catalogue updates and company info: www.tvh.be
complete range
Should you come across brushes with identical dimensions, and you are not sure what the difference is, please contact us.
286
BRUSHES
For all our latest catalogue updates and company info: www.tvh.be
complete range
Should you come across brushes with identical dimensions, and you are not sure what the difference is, please contact us.
287
BRUSHES
For all our latest catalogue updates and company info: www.tvh.be
complete range
Should you come across brushes with identical dimensions, and you are not sure what the difference is, please contact us.
288
BRUSHES
For all our latest catalogue updates and company info: www.tvh.be
complete range
Should you come across brushes with identical dimensions, and you are not sure what the difference is, please contact us.
289
BRUSHES
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complete range
Should you come across brushes with identical dimensions, and you are not sure what the difference is, please contact us.
290
BRUSHES
For all our latest catalogue updates and company info: www.tvh.be
complete range
Should you come across brushes with identical dimensions, and you are not sure what the difference is, please contact us.
291
BRUSHES
For all our latest catalogue updates and company info: www.tvh.be
complete range
Should you come across brushes with identical dimensions, and you are not sure what the difference is, please contact us.
292
BRUSHES
For all our latest catalogue updates and company info: www.tvh.be
complete range
Should you come across brushes with identical dimensions, and you are not sure what the difference is, please contact us.
293
BRUSHES
For all our latest catalogue updates and company info: www.tvh.be
complete range
Should you come across brushes with identical dimensions, and you are not sure what the difference is, please contact us.
294
BRUSHES
For all our latest catalogue updates and company info: www.tvh.be
complete range
Should you come across brushes with identical dimensions, and you are not sure what the difference is, please contact us.
295
BRUSHES
For all our latest catalogue updates and company info: www.tvh.be
complete range
Should you come across brushes with identical dimensions, and you are not sure what the difference is, please contact us.
296
BRUSHES
For all our latest catalogue updates and company info: www.tvh.be
complete range
Should you come across brushes with identical dimensions, and you are not sure what the difference is, please contact us.
297
BRUSHES
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complete range
Should you come across brushes with identical dimensions, and you are not sure what the difference is, please contact us.
298
BRUSHES
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complete range
Should you come across brushes with identical dimensions, and you are not sure what the difference is, please contact us.
299
BRUSHES
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complete range
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300
BRUSH KITS
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Part: 3
BRUSH KITS
301
BRUSH KITS
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complete range
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302
BRUSH KITS
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complete range
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303
BRUSH KITS
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complete range
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304
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305
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306
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307
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308
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309
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Part: 4
GENERAL BRUSH INFO
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Hard grades made from amorphous carbon (retort coal, carbon black, coke) have a robust cleaning and
long wearing characteristic. Normally used on commutators with flush mica and partially even with under-
cut mica.
APPLICATION: fractional h.p. motors, electrical tools, domestic machines up to 30 kW and up to 500 V,
contacts and current collectors.
Grades with high electrical resistance and graphite structure are used for difficult commutation and high
circumferential speed. In relation with good density values numerous fields of application result for these
grades.
APPLICATION: high rotating domestic appliances, electrical power tools, electrical gardening tools.
GRAPHITE GRADES:
Carbon graphite brushes consist of various graphite and carbon materials, having weak grinding effect due
to mineral ingredients. Mica must be undercut. The brush is able to grind off burnt spots on the commutator,
whilst speed and brush fire are low.
APPLICATION: machines with high speed, for turbo-alternator slip-rings and D.C. machines, micro motors,
fractional h.p. motors and dynamos.
High resistance, high transient voltage and large ratio of vertical and horizontal resistance, all facts which
influence favourably the suppression of commutating currents.
APPLICATION: Schorch and Schrage type A.C. commutator motors, D.C. up to 30 kW auxiliary brushes for
cross-field exitation, 3-phase commutator machines, repulsion motors, converters, fractional h.p. motors,
thyristor controlled motors etc.
ELECTRO-GRAPHITE GRADES:
Made from pre-graphitized carbon material and converted into electro-graphite under temperatures of
about 2500 °C for a prolonged period, thus freed from most impurities. The physical data such as resistance
density, strength etc. are more favourable than those of hard grades. It has furthermore good commutation,
consumption and short circuit proof features. Mica must be undercut.
APPLICATION: A.C. and D.C. motors, 3-phase commutators, traction motors, rotary phase converters, slip-
rings, arc welding, fractional h.p. motors, control dynamos.
Made from graphite and other carbons by adding copper and other metal powder. Excellent conductivity and
low voltage drop. The current density is essentially higher than with graphite brushes.
APPLICATION: earthing brushes, D.C. low voltage machines, starters slip-rings (exiters), synchronised
asynchronous motors, sliding contact line, etc.
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2) BRUSH ARRANGEMENT
A correct order of brushes on the commutator is necessary.
The brush arrangement should be as correct as possible to
guarantee good commutation and reduce lamella fire and balance
of the polar and electrolytic effects. Holders should be set near
the commutator say about 2,5 mm and should be in line with the
commutator segments except on those machines which have
circumferentially staggered brush holders. Since cathode brushes
(plus brush generator/minus brush motor) are mainly responsible
for the electrical corrosion of the slip body they should be
distributed equally over the width of the slip body.
The location of the anode brushes is of no importance but from the mechanical point of view advantageous if
the brushes of the neighbouring bolts are in line. This is particularly necessary in the case of reversible
motors due to frequent change of polarity. From the diagram of correct axial staggering you may see that
tracks must be covered by an equal number of positive and negative brushes.
4) BRUSH PRESSURE
Brush pressure has an essential influence on the correct operation of carbon brushes and is consequently an
important factor which is, however, very often neglected, resulting in the mechanical and electrical wear of
a carbon brush. The following table shows approximate brush pressures for various machines under normal
conditions.
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Picture 1:
a) edge chamfering is too heavy,
smooth brush run is negatively influenced.
Picture 2:
These examples clearly show how the edges of the segments should be removed and chamfered; an edge
chamfering is seldom necessary, if the commutator has been turned precisely.
Buildup of brush dust in the commutator slots in and around brush holders caused by wear must be
removed periodically in order to protect the commutator and the brushes.
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BRUSH SPARKING:
Brush sparking should only be objected to when it is damaging to the brush and/or collector.
Weak pin-points are harmless in nearly all cases and can be accepted even during continuous operation.
If there are reddish sparks, however, then the carbon material is being attacked and discolouration of the film
is apparent at the segment edges. Remedial steps are soon required if “streakers” are observed, whereas
green-glowing crackling areas call for immediate action.
In advance it must be stated that it is very difficult to maintain, which brush wear (reduction of unit of length
per time period or, more correct wear rate) can be regarded as normal without knowing the exact operating
conditions. The users of carbon brushes require the lowest brush wear in order to achieve longer service
intervals, less dust in the machine and, without saying, lower maintenance charges.
Too low brush wear can, however, in certain circumstances and after long operating times, lead to problems
as smooth and dense running surfaces can build up on the carbon brush as a result of the low brush wear.
These surfaces produce aerodynamic effects during high speed running which lead to a reduction in
brush contact. With low peripheral speeds and smooth running surfaces the carbon brush can in certain
adverse circumstances start oscillating when the sliding force is near to the static frictional force.
A minimum number of contact points are necessary for current commutation which are inevitably worn as a
result of the sliding process. The extent of this wear rate depends on the operating conditions, ambient
conditions and the carbon brush material.
Due to the multiplicity of influences it is difficult or even virtually impossible to give firm information about
the wear rate to be expected in individual cases.
Uneven brush wear should only be objected to if there are large differences in length after a long running
time. Smaller differences in length, e. g. 10 % should be considered as normal.
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Patchiness and burn marks are overwhelmingly caused by mechanical disturbances of the brush running.
Arcs are drawn, due to contact breaking, which lead to damage of the commutator or slip-ring surface.
Weak patches appear initially and these strengthen with longer running. The arced commutator or slip-ring
material together with the brush dust form the so-called burns.
A special type of patchy formation is shown on stand still commutators or slip-rings when, due to high
humidity, the carbon brush/rotor forms a galvanic element. If such conditions apply, one should place
insulating mats under the carbon brushes in order to avoid such markings.
GROOVING:
There is quite a list of operating conditions and external influences which lead to attack of the commutator or
slip-ring material and the formation of small tracks referred to as grooving. These grooves can expand in
unsuitable conditions to relatively deep and wide furrows over the whole area covered by the carbon brush.
These grooves do not represent any immediate danger for the operating security of a machine.
Expensive commutator copper will be worn out, however, so groove formation must be stopped by changing
the operating and ambient conditions. When assessing the groove depth one should note, that the strong
colour or lightness difference between coppery tracks and the patinated zones often looks like grooving
whereas, it is only a strong stripe formation of insignificant depth.
a) Foreign bodies:
Fine, hard, dust particles dispersed by the cooling air can come between the carbon brush running surface
and the collector and possibly even stick into the brush. These tear the patina and can lead after further
running, into the grooving of the commutator surface. Mineral constituents in natural graphite and carbon-
graphite grades also lead to weak collector attack or grooving. This fault is now virtually eliminated as
electrographite grades are nowadays predominantly used in large machines.
c) High humidity:
This aids the oxidation of the commutator material so that thick extraneous layers are formed. These will
then be fritted locally and lead to grooving as with cold commutators. Electrolysis also possibly plays a role in
conditions of high humidity.
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Brush oscillation can, dependent on intensity, lead relatively quick to damaging the brush flex as well as to
step formation at the base of the brush. Similarly, rattling can lead to breakage and splitting off of the brush
particularly in the running surface area. Brush oscillation and especially rattling also lead to contact breakage
between carbon brush and collector.
If a commutator or slip-ring is perfectly round and the brushes rattle then the general cause is excessive
friction (out-of-roundness protruding mica, etc. naturally give rise to vibrations).
Very smooth, polished patina whose formation has been encouraged by light load or even no load running
leads to the sliding of the carbon brush bordering on the limit of static friction. With other systems this
creates the so-called “stickslip-effect”. Carbon brushes with a correspondingly higher friction are excided into
a rocking oscillation which we refer to as “rattling”. The brush rattling can be reduced if the pressure finger of
the brush holder presses on the brush top, such that the direction of the force on the brush top bears on the
leading edge area. In this case the reaction moment at the brush becomes very small – this is of particular
importance when there is variable friction. When the friction force oscillates the reaction moment has the
effect of stabilizing the brush and compensates for the friction (see Fig. 1 and 1a).
A large gap between brush holder and commutator is also disadvantageous, as there would be a high turning
moment caused by the friction force pivoted on the bottom edge of the brush box.
Carbon brushes in reaction positions tend to rattle more easily than carbon brushes in trailing positions. The
rattling is not overcome by increasing the brush pressure as the frictional force would also be increased at
the same time.
On the other hand, current conduction causes micro-fine roughening of the patina as well as dust particles
through brush/commutator wear and this so-called “current-lubrication” reduces the friction. For the same
reason, a rattling brush-set can be quietened by lightly grinding the commutator. We should state here once
again, that when the commutator is reground or skimmed, the surface finish should not be too smooth.
Friction can also be reduced by applying a small amount of paraffin wax to the commutator or slip-ring by
means of a cotton cloth. This process does not always have a lasting success as the paraffin tends to
volatilize, especially at higher temperatures.
Should there be a danger from the outset that rattling will occur due to the operating conditions, then carbon
brushes should be chosen which have so-called, light load running abilities. The other brush requirements
would naturally also have to be taken into account.
If the operating conditions are so demanding that brush rattling can not be avoided than it is helpful to lightly
roughen the patina from time to time.
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• Mechanical causes:
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a) bulging
c) coming loose
d) shearing off
e) burning through
f) gas corrosion
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All of the above examples of patina are considered to be normal and represent good operating performances.
The differences in colour can in part be attributed to the different carbon grades used for the brushes.
i) Blurred spots or burn marks in the center of the bars, with small pools of molten metal at
the bar edges
Occurs through poor commutation or flawed commutator finish. Low brush pressure, vibrations, or unsuitable
brush grades could also be the cause.
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m) Medium burn marks at the bar edges, no pools of molten copper are yet visible
Burn marks on trailing bar edges are due to poor
reversal of current.
Burning in advanced stage, due to poor reversal of current and sparking at the brush
contact surface. During reversed operation, damages at the leading and trailing edges
have causes as found under position m) and n)
q) Burn streaks are defined as increased patchiness and copper beading found on
the commutator bars, caused by the trailing edge of the carbon brush
t) Like q), but no beads due to molten copper on the trailing edge
Caused through heavy sparking, due to poor reversal of current.
This in turn may have varying reasons.
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v) Relatively strong commutator attack with build-up of wear bands and burn ridge formation
Long running conditions with unspecified load on cold commutator. Often to be found where carbon brushes
with high metal content are used.
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NOTES
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NOTES
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