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AC Pullmor Motor (F-3) over heats...sparking at brushes/commutator; plastic melted

ToledoEdToledoEdOGR Forum Member DIGITAL SUBSCRIBER

My lionel Jet-car (6-38425) started slowing down, then it stopped.  I pulled the shell and removed the brush plate and noticed the plastic melted and sealed part of the brush slot opening which prevented the brush from touching the commutator. I filed away the melted  waste, cleaned the commutator and brushes. It ran on my test bed, OK. I did notice sparking at the point the brushes met the commutator.  I put the engine on my layout and ran it. Although it seemed to run at a slower speed then when it was new, but it was ok. After about 10 minutes of constant running it slowed then sopped. I opened it up and sure enough, plastic melted partially covering a brush. The engine seemed hot.  What causes the heat/sparking that I suspect melts the plastic?  Do I need new brushes, or brush plate, both...or is something else going on?  Need some help.  Oh, the track voltage does not exceed 17v.  The melting is shown.  Thanks.InkedIMG_5627_LI

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B bmoran4OGR Forum Member

At a minimum, a new brush plate, brushes, brush springs and a through cleaning of the commutator. If you are not so inclined to perform some work,  it seems Lionel does have the 630-8332-150 motor available as a complete unit.

As for a cause of the heat build up, I would look for a dirty and/or shorted commutator/armature. Be sure to clear the carbon deposits between the commutator poles. In addition to that, upkeep on basic maintenance on lubricating the drive mechanism and axles and keeping everything clear of carpet fiber, hair etc.

Here is the breakdown of the motor:

exploded view.

Parts:

https://www.lionelsupport.com/...2FE-B04407D12F0B257F

Motor Unit Complete:

https://www.lionelsupport.com/...amp;CFTOKEN=64388926

Last edited by bmoran4
B bmoran4OGR Forum Member

All the parts, including brushes, are available from Lionel on the link in my above post:

@bmoran4 posted:


Parts:

https://www.lionelsupport.com/...2FE-B04407D12F0B257F

Motor Unit Complete:

https://www.lionelsupport.com/...amp;CFTOKEN=64388926

If you don't want to purchase direct from Lionel, you can search for Lionel Part 8570-150: https://www.google.com/search?...p;oq=lionel+8507-150 However, I would expect these brushes to originate from Lionel and may not address your quality control concerns. You could substitute Lionel 622-121/226E-92 brushes from just about any parts supplier and just solder wires to the brush spring holders.

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