Excello 602 motor problem

[zeefoes]

Just acquired an excello 602 but when I try to power it up it seems like the motor isn't able to drive the spindle.. When the speed is set to low the motor is able to rotate the spindle slowly, but as I turn up the speed the spindle stops but the motor sounds like it's going faster. Also the motor gets extremely hot after a short while of this.

Can anyone help me out?

[Al_The_Man]

You either have a problem with the Vari-speed pulley or the gear box, if this is the original GE pancake motor?
Most likely the Vari-speed.
The motor runs at a fixed rpm, ~1745rpm.
I converted mine to VFD with 1:1 timing pulley and use the gear box for low speed machining.
Al.

[zeefoes]

What is the easiest way to access the varispeed pulley so I don't have to disassemble the machine too much. Any tips on what I should be looking for once I get in there? Need some help I'm new to the whole servicing aspect.

[Al_The_Man]

The top cover comes off easily, you may have a belt shot, you can run the motor and watch the pulley/belt with the top cover removed.
Do you have the 602 manual?
Al.

[zeefoes]

We took off the RPM cover, set the speed to max, reinstalled it, and manually rotated the motor while lowering the speed setting. After doing this it seemed to work just fine. Would cycle through the speeds just fine, and worked on high gear as well.

Well we ended up testing it again. We turned it on and it was already set to like around 200-400 rpm on low gear.. then we turned it off and switched it to high and it just wouldn't go. So we switched it back to low. The situation now is that it only works on low gear from 85 rpm to like 300 or something. After 300 it seems like everything slows down and comes to a stop. Once this happens we have to manually rotate the motor while lowering the speed setting back to 85. Also now once we take off the RPM cover the motor seems like it's struggling, doesn't go nearly as fast as when we first removed it and turned it on.

Ugh, don't know what to do. Probably going to call someone.

[Al_The_Man]

The Varispeed action is identical in both high and low.
IIRC the gear box in high is 1:1 and in low is ~6.25:1
One problem I had was the bronze gear shifter fork that moves from low to high gear had worn down, I used some stock bronze to build the fork up by silver soldering the new piece on.
The Varispeed mechanism is not that complicated to dissasemble and check, also check the belt, I should have the number if you need it.
BTW, Excello recommended switching to Transmission fluid for the gear box lube.
Al.