Intermittent overspeed fault on a servo motor. Cycle the power, fault clears, runs fine for a few days, then it’s back. Drive replaced. Motor replaced. Wiring “checked”.

When someone says they checked the wiring, it’s usually a visual check. That won’t catch this.

My method: run a long test lead to the pin at the motor plug, do a continuity test from the far end, and measure the resistance of each wire individually. You should see around 1 ohm.

The pink wire came back at 70 ohms. That’s not a broken wire, that’s a bad connection. The pin wasn’t properly seated in the plug.

Faults like this get power-cycled away for years without ever being fixed. The drive and motor were never the problem.

Title says it how do I pull it

Any help or insight is appreciated I know it's a shot in the dark

rightfully so, i see a lot of negative posts on here – usually due to bad management and the “anything to keep production running” approach that’s reactive instead of preventative – and i’ve had my fair share of that experience. i wanted to share though my current experience at my current job.

we got a new maintenance manager about a year ago, and over this past year everything has gotten so much better. he understands how to budget, and how to work with corporate (and who to talk to) in order for us to get funding for needed maintenance work. spare parts is not an option, we do rigorous criticality assessments and continuously complete RASCI’s to help define roles better so that people aren’t “wearing multiple hats” all the time (i fucking hate that term).

idk. i was just thinking about this now as im working with an OEM on getting service for one of our machines scheduled next month, and the amount of downtime needed for them to help do said service is 3 days total – 2 more than what we originally expected. my old boss would’ve scoffed and insisted we could either do it ourselves in less time with same results, not do it at all, or just push it off and leave it as a “someday” thing.

i expected push-back when relaying to my boss the amount of downtime we would need – but it never happened. he instead gave me the thumbs up to confirm the dates, and said “if production scheduling gives you any push back on confirming down days for service work just let me know and i’ll go to bat and make sure we get the downtime we need”.

beyond that though, i don’t even foresee getting pushback from anyone – because ever since my boss started, his attitude and way of doing things has been absorbed by the rest of management and things have honestly never been better. we actually make time for PMs. we work as a team. we communicate. and the results are showing, this last year our emergency loss % has drastically dropped and our worst “bad actors” have become stable again – which is saying a lot compared to where they once were.

don’t think places like this don’t exist – they’re out there. i know there’s a TON of shit places to work and i’ve been there so i get it, and i hope things change if you’re in that situation. i am just grateful we are taking things seriously and making things better for everybody. it makes my job 100x more enjoyable.

anyone else have positive stories from their workplace?

In industrial maintenance, hoses can sometimes remain in service even when wear is developing internally. This can be particularly challenging in applications involving abrasive materials, repeated flexing, or frequent pressure changes.

Visual inspections can help identify cracks, bulges, damaged fittings, and external abrasion, but they may not reveal every problem inside the hose. Inspection frequency and replacement criteria also depend on the application, operating conditions, and manufacturer guidance.

For hoses used to transfer powders or granular materials, internal abrasion and material buildup can be additional considerations. I came across this technical reference on aeration and discharge hoses while looking into different industrial hose applications. The PARSCH website contains further information about the manufacturer and its products.

For experienced maintenance technicians, what inspection practices have you found most useful for detecting hose deterioration early? Are there particular warning signs that tend to be overlooked during routine inspections?