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It usually is something to do with the faces of the commutators as others and the notes on Doug Peck's site have cited.  A good thorough check of them and their surroundings is all part of trying to address the issue -- which almost inevitably strikes most Gilbert steam engines.  The drill/drill press and emory paper "facing" of the commutators usually works, but may not last as long as turning them on a jeweler's lathe -- at least that's been my experience with both treatments.  The problem is having or finding someone with a small lathe (and that knows what they're doing not to remove too much copper in the process).  The expert that used to do them for me no longer does.  Pity.  Did great work.  You need also to be careful not to sever the wire wound around each of the three segment posts when facing the comms.  Some of the armatures sold by Doug Peck have new commutators.  You might want to check his web site for those.  In summary, check the following for proper operating condition:

  • front armature bearing -- intact?  worn out? 
  • rear armature bearing -- intact? worn out?
  • shaft of armature -- fore/aft of the windings, I've had some that were worn thin, usually fore
  • front thrust washer(s) (0.020"/0.010"), aft thrust washer (0.005" with oil splash guard armature)
  • brush springs, brushes, brush tubes
  • brush holder intact (not cracked)
  • armature windings (intact, good connection to posts)
  • armature commutators (intact, cleaned, shiny, even/flat, continuity and like resistance between all segments, refaced if/when necessary/possible)
  • some, but not a lot of axial travel when assembled
  • free spinning by hand in both directions when assembled (without brushes or choo-choo)
  • drive gear centered on axle
  • choo-choo gear free-spinning, but not too much play
  • grease on worm, drive, and choo-choo gears
  • medium oil on front armature bearing
  • light oil (very sparingly) on rear armature bearing and oil wick

Don't take it personally.  The "syndrome" strikes many an innocent Flyer steam engine.  

Dave

Last edited by Sgaugian

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