GEK-91659-7

H83837D
11 May 2004

ELECTRIC DRIVE
DRILLING EQUIPMENT
FOR

EMERI INTERNATIONAL

GE 752 – HIGH TORQUE

HORIZONTAL DRILLING MOTOR

DRAWWORK MOTORS

Customer Order No. 2003/27A

GE Requisition No. 420-54461

These instructions do not purport to cover all details or variations in equipment nor to provide for every possible contingency to be met in connection with installation, operation, or
maintenance. Should further information be desired or should particular problems arise which are not covered sufficiently for the user’s purposes, the matter should be referred to
the General Electric Company. Any applicable Federal, State or local regulations or company safety or operating rules must take precedence over any instructions given in this
manual. GE has no obligation to keep the material up to date after the original publication.

THERE ARE NO WARRANTIES OF ACCURACY, MERCHANTABILITY OR FITNESS FOR PARTICULAR PURPOSE.

Verify numbers for parts, tools or material by using the Renewal Parts or Tool Catalogs or contact your General Electric
representative for assistance.
Do not order from this publication.
Hunt Engine, Inc. H83837D
Page 1 of 2 11 MAY 2004

CONTENTS

TAB DESCRIPTION REFERENCE

A. MAINTENANCE - GE752 MOTOR

GENERAL MAINTENANCE OF ELECTRICAL ROTATING APPARATUS GEI-85166
COMMUTATOR MAINTENANCE GEI-85167A
HORIZONTAL DRILLING MOTOR/GENERATOR TYPE GE752 GEK-91658
MODEL DIFFERENCE SHEET (MDS-UB3) GEK-91658
INSPECTION AND MAINTENANCE SCHEDULE GEK-47175B
LUBRICATION SPECIFICATIONS GEI-73029C
SHIPPING INSTRUCTIONS GEI-69852C
RECOMMENDED STORAGE INSTRUCTIONS GEK-61777
REMOVING MOTORS AND GENERATORS FROM STORAGE GEK-2818
INSTALLATION INSTRUCTIONS FOR DRILLING MOTORS & GENERATORS GEK-43814A
BRUSHOLDER CARBONWAY RESTORATION GEI-91045B
VACUUM PRESSURE IMPREGNATION (VP) PROCESS GEK-101183D
RESISTANCE THERMOMETER S9074PBY
PRESSURE SWITCH - EXPLOSION PROOF E-57
SPACE HEATER BP7G7A WATLOW-BATAVIA
B. RENEWAL PARTS - GE752 MOTOR
COVER SHEET GEX-12149
INDEX GEX-12149
HOW TO USE THIS PARTS CATALOG TK-2277B
PARTS BULLETINS
AUXILIARY SWITCH ASSEMBLY (3261) DWG41A230022
CONNECTION BOX ASSY – RENEWAL PARTS LIST RPL4995G02
ILLUSTRATION – RENEWAL PARTS LISTS 4995G2-RPL
TERMINAL BOARD PB-77000-003A
C.B. PRESSURIZING EQUIPMENT (2964) PB-40104A
HEATER ASSEMBLY (3981) PB-40106A-MOD
DRILLING MOTOR ARB3B PB-31101-038
PRESSURE SWITCH ASSEMBLY (2965) PB-40107-002
C. BLOWER MOTOR ASSEMBLY – HUNT AIRDYNE (4991G03)
INSTALLATION, OPERATING AND
MAINTENANCE INSTRUCTIONS FILE: AIRIOMI
RENEWAL PARTS LIST RPL4991G03
ILLUSTRATION-RENEWAL PARTS LIST 4991RPL
MOTOR DATA SHEET 5019MDS
INSTRUCTION MANUAL GE
OUTLINE BLOWER MOTOR ASSY 4991S
BLOWER TEST PROCEDURE QCW4-10-01E
TEST REPORT S/N 83837D-1 THRU 83837D-4 QCD129
HUNT ENGINE WARRANTY POLICY
D. AIR OUTLET DUCT ASSY
GENERAL ARRANGEMENT DRAWING 4114S
Hunt Engine, Inc. H83837D
Page 2 of 2 11 MAY 2004

E. HUNT AIRCURE (2092)

INSTALLATION, OPERATING &
MAINTENANCE INSTRUCTIONS FILE: AIRCIOMI
GENERAL ARRANGEMENT DRAWING 2092S
F. SPEED SENSOR (4539G2)
GENERAL ARRANGEMENT DRAWING 4539G02S
RENEWAL PARTS LIST RPL4539
ILLUSTRATION – RENEWAL PARTS LIST 4539RPL
CATALOG DATA SHEETS EEX GP02
INSTALLATION & OPERATING INSTRUCTIONS HUBNER
PTB CERTIFICATE OF CONFORMITY EX 82/1087
DECLARATION OF CONFORMITY Eex de 11C T6
 /
 / 

  
 
 

 
 
  



) $)*(+* %$) % $%* &+(&%(* *% %,( "" * ") %( ,( * %$) $ '+ &#$* $%( *% &(%,  %( ,(. &%)) " %$* $$. *%  #* $ %$$* %$ - * $)*""* %$ %&(* %$ %( # $*/
$$ %+" +(*( $%(#* %$  ) ( %( )%+" &(* +"( &(%"#) ( ) -  ( $%* %,( )+  $*". %( * +)() &+(&%)) * #**( )%+"  ((( *%
 $.
&&" " (" ** %( "%" (+"* %$) %( %#&$. )*. %( %&(* $ (+") #+)* *! &($ %,( $. $)*(+* %$)  ,$ $ * ) #*( "
 ) $% %" * %$ *% !& *
#*( " +& *% * *( * %(  $" &+" * %$

             

(". %+$() &( '(*) *&&#) &( $*("# . +)"% *! %-# (*) &( &&# *#& ) &( &%** .&+(
 ('()%**", &( ))")*%
& %&* &(( (&$ *!") '+#"*"&%
!
!
    

 4. Clean the commutator string band and cable

connections.
 

                               5. Look for defects while cleaning. Check varĆ

                                     nished surfaces of the armature and field coils
IN THE LOCOMOTIVE . . . . . . . . . . . . . . . . . . . . . . . . 2 for cracks, flaking, etc.
DISASSEMBLED APPARATUS . . . . . . . . . . . . . . . . . 2
                   
                                   
ARMATURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
COMMUTATORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
FIELD COILS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
BRUSHES AND BRUSHĆHOLDERS . . . . . . . . . . . 13
ARMATURE BEARINGS . . . . . . . . . . . . . . . . . . . . . 14
MOTOR AXLE BEARINGS . . . . . . . . . . . . . . . . . . . 16
PREPARATION OF VARNISHES . . . . . . . . . . . . . . 17
                    

 b. Keep the vaporized cleaning solution at
This GENERAL MAINTENANCE publication is deĆ
signed to be used with the specific instruction books
prepared for the electrical rotating equipment used on
the locomotive. In most cases, the specific device
publication will make reference to the GENERAL MAINĆ
TENANCE publication for maintenance and repairs of
rotating equipment components.
 pors as this amount of heat could damage
  

Determine a schedule for cleaning electric rotating
apparatus based on operating conditions.
1. Clean dirt from openings, inspection covers,
axleĆcap covers, armature bearing caps, lubriĆ
cantĆfiller caps, and terminal connections.
2. Remove the commutator covers and blow out
the interior of the apparatus with dry comĆ
pressed air (maximum pressure, 70 pounds).
Remove dirt, oil, or grease accumulations from
accessible parts inside the frame.
3. Clean Teflon"* insulators on brushĆholder supĆ
ports. Do not sand or paint insulators. Wipe with
a clean, dry cloth.
* Reg. tradeĆmark of E.l. DuPont de Nemours Co.
2
 
Parts can be cleaned using one of the following
methods:
1. With a vapor degreaser:
a. Bring the cleaning solution to a boil and alĆ
low the vapor line to rise to the condenser
coils at top of the tank.
about 120 C (248 F).
c. Lower the part to be cleaned into the vapor
laden atmosphere so the vapor will conĆ
dense on the apparatus.
d. Introduce the apparatus to the cleaning meĆ
dium intermittently. Do not allow the part to
reach the temperature of the solution or vaĆ
the insulation.
e. To speed the removal of heavy dirt accumuĆ
lations, spray hot solution directly from the
tank onto the apparatus. The temperature of
the solution must be below its boiling point.
f. Remove the cleaned part from the degreasĆ
er, drain, and cool.
2. With a steam jenny:
a. Heat a washing compound (such as Oakite
and water) in a steam jenny tank until the
temperature of the solution in the tank reachĆ
es 100 C (212 F).
b. Suspend the part in a position that is accesĆ
sible from all directions to a direct flow from
the hose.
c. Clean parts and allow them to cool and dry.
Use compressed air to blow off excess moisĆ
ture.
 & 

 

 &


d. If varnish is to be applied or electric windings
are involved, bake the part until all moisture
is removed.
3. With cleaners:

 !## ($!+#)( ".  )$-
#$' #!""! . # *( ('$*( $'
)! #*'.  *( ,)$*) %'$%' %'*)$#(
$' (). reading varies more than plus or minus five
2. Check for open or shortĆcircuited armature coils
as follows:
(BarĆtoĆBar Resistance Test)
a. Pass a regulated amount of current through
armature coils.
b. Read the voltage drop between the adjacent
commutator bars with a millivoltmeter. If the
 $ #$) #! ($!+#) *"( percent (approximately), it indicates there is
 ( ($!+#)( $#!. # &*)!. +#)!) a defective or shortĆcircuited coil.
'(
c. Should such a variation be found, disconĆ

+$ $#)) $ ($!+#) ,) ) ( #
nect the armature coil from commutator and
 $ #$) -%$( ($!+#) )$ !" $' (%' (
check for the defect in the commutator or the
 ('+ *)$# ())"#)( ((* . )
coil.
"#*)*'' $ ) ($!+#)


a. Select a suitable solvent as follows:



1) For insulation, use a nonĆoily, quick dryĆ $#"$!  "!%  $ 
ing cleaner.
To remove the armature from the frame see individĆ
2) For pinion and bearing fits, shaft tapers, ual instructions.
and metal surfaces, use a cleaner which
1. Keep the commutator covered with heavy paĆ
will not leave an oily deposit on the finĆ
per.
ished surface.
2. Avoid damage to windings and bearing fits.
3) For antifriction bearings, use a cleaner
which will not completely remove the oil 3. Place the armature in a wooden cradle.
film from finished surfaces. Kerosene,
4. To hoist small armatures in a horizontal position,
petroleum spirits, or other petroleum
use a rope sling around the shaft ends. Do not
solvents are satisfactory.
permit the sling to pull against the commutator.
b. Dip a clean, lintless cloth into the solvent and 5. To hoist small armatures in a vertical position,
wipe off the part. Do not dip insulating mateĆ use a lifting eye, either screwed to the pinion
rials in solvent. end or bolted to the end of the generator shaft.

    6. When hoisting a large generator armature in the

1. Lift the brushes and apply a megohmmeter test
to the armature and field coils.
a. A reading of one megohm or more normally
indicates that insulation is satisfactory.
b. Reading of less than one megohm indicates
that insulation creepages are dirty or the inĆ
sulation is moist. In such a case, follow the
overhaul procedure outlined in the particular
apparatus instructions.
horizontal position:
a. Bolt an adapter to the coupling flange to supĆ
port the coupling end.
b. Place a sling around the adapter and the
shaft, with a piece of heavy felt between the
bearing surface of the shaft and the sling.
See Fig. 1.
7. To turn the generator armatures from the horiĆ
zontal to the vertical position.

3



   
 

ground in the armature, rewind the armature. If the arĆ
mature is in good condition and bands do not need reĆ
placing, perform steps 1, 4, 5, 6 and 10 as follows.
FIG. 1. METHOD OF LIFTING GENERATOR
ARMATURE HORIZONTALLY AND SETTING IN
TURNĆOVER FIXTURE. EĆ9832.
a. Place the armature, with the couplingĆend
fixture assembled, in a turning fixture. See
Fig. 2.
b. Bolt a lifting bail to the bearing end of the
shaft.
c Attach a cable from the hoist to the lifting
bail.
d. Slowly raise the commutator end to a vertical
position while keeping the coupling end in
the turning fixture.
e. Reverse the procedure to move the armaĆ
ture from a vertical to a horizontal position.

Examine the armature for the following defects:
1. Damaged bands, wedges, coils, insulation, and
commutator (see COMMUTATORS).
2. Loose armature bands and core wedges.
3. Bands with thrown solder.
4. Blistered, flaked, or cracked coil insulation.
4
If the apparatus has failed in service from a short or
1. Clean creepage surfaces, and all other exposed
surfaces.
2. Remove armature bands and bandingĆbase inĆ
sulation.
3. Apply narrow temporary bands to each end
winding. Use fiber material to protect windings.
4. Heat the armature in oven to 120 to 140 C (248
to 284 F) for two hours (small armatures) and to
six hours (large armatures).
5. Dip the armature at 90 to 100 C (194 to 212
F) into GEĆA15B19B varnish as follows (see
PREPARATION OF VARNISHES for viscosity):
a. Hold motor armatures and small generator
armatures on a swivel hook with commutaĆ
tor end up. Immerse the armature up to the
commutator risers, and hold for eight minĆ
utes.
b. Lower large armatures horizontally until botĆ
tom windings are immersed, and rotate the
armature slowly in this position for ten minĆ
utes. See Fig. 3.
c. Raise armature and drain. Spin small armaĆ
tures to throw off excess varnish. Incline
large armatures at an angle of 45 degrees,
and drain five minutes.
d. Wipe varnish from shaft.
6. Place the armature in an oven in a vertical posiĆ
tion with commutator end up. Bake for seven to
18 hours at an oven temperature of 120 C to 150
C (248 to 302 F).
7. Measure the insulation resistance while armaĆ
ture is hot. Continue baking until insulation
resistance is at least one megohm.
8. Replace temporary bands with permanent
binding.
 

    


INSERTING ARMATURE IN TURNING FIXTURE ARMATURE PARTLY TURNED

FIG. 2. TURNING GENERATOR ARMATURE. EĆ9833A.

9. Repeat Items 5 and 6 twice for the second dip


and bake. Two dips are usually sufficient for reĆ
conditioned armatures; three dips are necesĆ Have the armature dynamically balanced after any
sary for rewound armatures. of the following operations:

10. Allow the armature to cool to room temperature. 1. Armature has been rewound or armature coils
Then apply highĆpotential and barĆtoĆbar reĆ repaired.
sistance tests. See HIGH POTENTIAL TEST unĆ
2. Armature has been rebanded.
der FIELD COILS.
3. Armature has been dipped and baked.
11. If an armature has glass banding, see
individual instructions for the banding proceĆ 4. Commutator has been repaired (other than
dure. tightening or turning).

5
( 
(   

REF. DESCRIPTION
1 PAN OF VARNISH
2 INSERT PIECE OF FIBER BETWEEN SHAFT
AND LIFTING CABLE FIG. 4. METHOD OF POLISHING
3 SPREADER BAR COMMUTATOR. EĆ40562.
4 BAR USED TO ROTATE ARMATURE
5 ADAPTER BOLTED TO COUPLING FLANGE
6 SLEEVE TO PERMIT ADAPTER TO TURN

3. Blow away dust and sand with clean, dry, comĆ

FIG. 3. ROLLING GENERATOR ARMATURE IN PAN pressed air (70 psi maximum).
OF VARNISH. EĆ657A.
  
    "  " #
     
!     


   #    
$"$! "$ %#  "!
     !   
       
If the commutator is dirty, blackened, or slightly
    
rough, use fine sandpaper and sand the surface as folĆ
lows:
&'% "$! "$ %#
1. Run the machine at oneĆthird normal speed. If the commutator has undergone mild flashovers,
grooving, or burning, use the following procedure for
2. Hold the sandpaper against the surface and, reconditioning.
with a light, even pressure, work it back and
forth longitudinally across the commutator. 1. Use a rigidly supported grinding fixture.

6
 )

 

 ) 
2. Mount the supporting adapter to the magnet

frame (in place of one of the brushĆholders).
3. Be sure to keep commutator round. Maximum
commutator runout for armatures which run at a
top speed of 1800 rpm or higher, is 0.001 inch.
Maximum commutator runout for armatures
which run under top speed of 1800 rpm is 0.002
inch.
4. Check the commutator with a dial indicator for
concentricity with the bearing seats.
5. Blow away dust and sand.
(%#!#  ! 
If the surface is badly worn, burned, or scarred, reĆ
move the armature from the frame and turn the comĆ
mutator. See individual apparatus instructions.
1. Place the armature in a lathe.
a. If adapters for the armature bearing are
available, mount the armature in its bearĆ
ings.
b. If bearing adapters are not available, true up
the commutator surface with bearing seats.
This may require straightening of the armaĆ
ture shaft. Check the shaft concentricity with
a dial indicator.
2. Cover the windings to prevent entrance of chips
and dust.
3. Set up a cutting tool for turning copper, and set
lathe speed to give a commutator surface
speed of 300 rpm.
4. Take clean, smooth cuts to remove just enough
material to provide a smooth surface. Do not
drag the copper over the mica when taking cuts,
and do not burn the tool.
5. After turning, clean up the front ends of the bars
with a 1/16Ćinch radius file.
#%(''!# !  !
1. Undercut mica to a depth specified in individual
motor instructions. Use a saw of correct size.
DO NOT ENLARGE SLOTS.
2. Remove sharp edges from the bars with a hand
scraper or knife. Do not bevel edges of segĆ
ments.
3. Clean slots to remove fins, chips, or foreign maĆ
terial.
4. Blow out the commutator.
!#" %!#!# # $"!& !#
 ! 
1. Place the armature in a grinding machine if
available.
a. If adapters for the armature bearings are
available, mount the armature in its own
bearings.
b. If adapters are not available, mount the arĆ
mature between its centers and true up the
commutator surface with respect to bearing
seats. Check concentricity with a dial indicaĆ
tor.
2. If a grinding machine is not available, leave the
armature in the lathe without disturbing the setĆ
up made for turning. Mount a grinding attachĆ
ment in the tool post.
3. Wrap the armature windings or use a suction atĆ
tachment to keep copper dust out of the windĆ
ings
4. Adjust the machine speed for grinding copper.
Use a finishingĆgrade wheel.
5. Grind the commutator. After completing a cut,
traverse the stones back and forth longitudinally
without feeding in, until there is no more cutting
action.
6. Polish the surface with fine sandpaper.
7. Blow out the commutator.
7
#

# 

   
 

     
     

    
          


 
     


FIG. 5. COMMUTATOR DAMAGED BY OVERHEATING. EĆ8374.

! "!  

  (!&% $#'$ &! $+'$
#! # $##!   #!# #! ! !(
#! "  "# ! #$! "# $ #  !
! $!

 # #!# #! " !% ! # (
#%  #   "$! ! !#
"# "" !  !#"
!'&&!$%  % %&$& !%$(  !
& !!)  "$'&! % &! "$( & %$!'% !$
&  '$* &! "$%! 
 $ $'$ !(%   !% )
!)  !'& !""$ '%&
 %  ! +& &&  ! &   ! &
$ !% &! "$( &  & %!$& $'&
 !$   ' '&&$ $ !  $* )!!+
 %'$
 # # !#$! " #  %! %#(

(! !* ! && )& &$ %
 "$! %  !  $%# # ## 
 "$&!$ '%& $ & ! &$!% ' & &
# 
'$  "$!%% % !"&   #'" &
%'& !) 
 # #  " #  "!# %#
"$! $"# # # $ !#  # 

 $  ! " # # %#'    ' $ %# #  "  ' (
#! %# # # !#$! $# # 
  # & "#' !$#" " !$ # $ "

 
       






REF. DESCRIPTION
1 GRINDING WHEEL
REF. DESCRIPTION 2 COMMUTATOR
1 SAW CUTTER
3 FLEXIBLE DUST SUCTION PIPE
2 CUTTING ATTACHMENT DRIVE
3 CUTTING ATTACHMENT POST
4 LATHE CROSS FEED FIG. 7. GRINDING THE COMMUTATOR IN A
GRINDING MACHINE. EĆ1875A.
FIG. 6. UNDERCUTTING MICA IN LATHE. EĆ1876.
3. When a VeeĆbound commutator is to be solĆ
dered, proceed as follows if a soldering pot is
7. Direct the air stream through the inspection covĆ used:
er into the mica grooves and clean the commuĆ
a. Heat the armature evenly until the commutaĆ
tator over its full length until no sparking can be
tor temperature is 100 C (212 F).
detected.
b. Place the armature in a press and apply
8. Increase the armature speed and repeat the pressure to the commutator cap. See indiĆ
foregoing procedure until full voltage has been vidual apparatus instructions for the exact
applied to the armature. amount.

c. Loosen the ring nut or the commutator bolts.


1. Brace the open risers of traction generators
(which are not TIG WELDED) to the armature
coils with silver solder, GE No. B20D6.
2. Solder other commutator risers to the armature
leads with pure tin solder, GE No. B20C2.
See individual apparatus instructions.
d. Remove pressure and solder as required.
e. While the commutator is still hot, apply the
same pressure (see item b) to the cap and
retighten nut or bolts the same number of
turns.

9
"
"     


ring nut or bolts is appreciable, inspect other

similar commutators for looseness.


   




 


2. Looseness can be corrected by tightening the

ring nut or the commutator bolts.

3. If string banding was removed, inspect the seal

1. Keep the mica segments of the commutator between the copper segments and the mica
undercut to the correct depth. cones on archĆbound commutators. If defecĆ
tive, replace this seal with a GEĆA15F4B seal.

 

Give the commutator a seasoning cycle if any of the

following commutator repairs are made:

1. When a new (unseasoned) commutator is

mounted on the armature.
2. Keep the surface of the commutator clean and
smooth. Sand or stone the commutator when 2. When a commutator that was found to be loose
signs of roughness or dirt appear. Turn and has been retightened.
polish the commutator if it becomes badly
worn or burned. 3. When a VeeĆbound commutator is loosened for
soldering the armature leads in a soldering pot.

Specific seasoning instructions will be sent upon reĆ

quest. If seasoning apparatus is not available, a seaĆ
soned commutator may be ordered from GE.



 !
3. Keep the commutator surface and brushes
free from all contact with oil or grease. 1. Inspect for loose or damaged connections.
4. Keep the string band clean. Apply a coat of
2. Visually inspect the condition of the coil insulaĆ
GEĆA15B17A varnish to maintain surface
finish. DO NOT PAINT OVER DIRT. tion.

FIG. 8. RULES FOR PROPER MAINTENANCE. 3. Clean dirt, dust, oil, and grease away from
EĆ40563. spaces between coils and around corners beĆ
tween the coils and the frame.

4. Look for burned or charred insulation; where

found, replace defective coils.
!
5. If varnish and insulation appear to be in good
1. If commutator looseness is suspected, check condition after cleaning and no other defects
the tightness of the bolts according to individual are noticed, removal of the coils from frame may
apparatus instructions. If the advance of the be unnecessary.

10
 )
       )


# #"&#"" $(" " $! $!&'$

!#(
1. Remove the field coils. See FIELDĆCOIL REĆ
MOVAL in individual apparatus instructions. 1. Clean the coils and frame. See CLEANING.

2. Test the insulation with a megohmmeter. If the

2. Clean the coil, the coil terminals, and the surĆ
faces of the pole piece and magnet frame.
3. Heat the coil in an oven to 100 C (212 F) to reĆ
move moisture. Then dip (or paint) in
GEĆA15B17A varnish heated to 90 C (194 F).
4. Bake the coil in oven for eight hours at 100 to
120 C (212 to 248 F).
5. Again, while the coil is hot, dip in varnish.
reading is 1 megohm or higher, remove external
leads and rubber bushings, and paint or spray
the complete inside frame assembly with
GEĆA15B17A varnish.
3. Bake the frame in an oven for four hours, or air
dry for eight hours.
4. Clean varnish from machined surfaces.
5. Cool the coils to room temperature, and apply a
highĆpotential test between the coils and frame.

6. Allow the coil to cool, then, scrape varnish from )#&"& %&
electrical contact surfaces.
      
7. Clean the magnet frame and paint the interior    
     
surfaces (except pole seats) with GEĆA15B17A    
  
varnish. Do not permit varnish to remain on pole
piece seats.
8. If the coil is light enough to be handled easily,
even when hot, heat coil to 100 to 120 C (212 to
248 F) and install in magnet frame. If the coil is
heavy, install in magnet frame cold, and see inĆ
dividual instructions before tightening. Use
original shims and new lock washers when inĆ
stalling pole pieces.
9. Connect the field coils and insulate the connecĆ
tions according to instructions written for the
specific device.
   
1. Make sure field coils are clean.
2. Connect one lead of a megohmmeter to a coil
terminal, and the other lead to the magnet
frame. Measure the insulation resistance. Do
not apply highĆpotential test if the insulation reĆ
sistance is less than one megohm.
3. Disconnect the megohmmeter and connect
highĆpotential testing apparatus. Refer to testĆ
ing instructions on individual apparatus for
proper test voltage. Apply test voltage for 60 seĆ
conds.

10. Measure the insulation resistance of a field cirĆ
cuit with a megohmmeter. If it is not less than
one megohm at room temperature, apply
highĆpotential test between coils and frame. If
megohmmeter reading is less than 1 megĆ
ohm, bake the assembly to dry out moisture.
11. After coils are reassembled in the frame, brush
or spray the interior of the frame with another
coat of GEĆA15B17A varnish, and allow it to air
dry.
#$&)$'& %&%
Measure the resistance of the field coils by one of
the following methods:
1. The resistance method (least accurate):
a. If the armature is in the motor, raise all
brushes so that they do not make electrical
contact with the commutator.
b. Connect an ammeter in the coil circuit, and a
voltmeter across the circuit. Test the excitĆ
11



   
 


ingĆfield coils circuit and the commutatĆ

AMMETER 30 AMP.
ingĆfield coils circuit separately. 9Ć1/2 IN. DIA. TYPE RĆ4 CAT. 114276
100 TO 3 IN. DIA. TYPE AO CAT. 286200
120
c. Apply voltage to the coils and compute the VOLTS 60
resistance from the instrument readings for AĆC TURNS
voltage and current. ENCLOSED SAFETY 60
AMP. TRUMBULL
180
SWITCH CAT. 36222
TURNS
Resistance (R) = Voltage (E)
Current (I) OPEN KNIFE
SWITCHES
d. If the resistance is five percent less than 30 AMP. FUSES
90 TURNS
standard at corresponding temperature as
given in individual apparatus instructions, PREVENTS DAMAGE TO
METER WHEN BURNINGĆOUT
measure the voltage drop across each coil, SHORTED COIL
and compare with the quotient obtained by 4 IN. WIDE. NO. 20 GA.
dividing the given standard value by the OR THINNER
number of coils in the circuit being meaĆ
5"
sured.
FIELD
COIL
      
9Ć1/2"
           !
 4"

5"

e. Replace the defective coil.

180 NO. 10 B & S GA
2. The impedance test method: TURNS 5" 12" 5" DOUBLE COTTONĆ
COVERED WIRE
a. Raise the brushes so they do not make elecĆ 60 90 TURNS
trical contact with the commutator, disconĆ TURNS
nect the flexible connection strap from the REMOVABLE PIECE. TWO OR
THREE SIZES TO FIT DIFFERENT
brushĆholder and connect one of the test cirĆ SIZE HOLES IN FIELD COILS
cuit leads to it.
FIG. 9. GROWLER TEST FOR FIELD COILS.
b. Connect an ammeter in the circuit, and a EĆ40564.
voltmeter across the circuit. Apply a 60 cycle
aĆc voltage and measure voltage drop
across the circuit. Compare the drop with
a. Use a test apparatus construction as shown
the standard value given in individual inĆ
in Fig. 9.
structions.

c. If the voltage is low for the entire field circuit,
measure the voltage drop across each coil
and compare it with the average value of all
the coils as measured separately.
d. Replace a lowĆvoltage coil.
b. Adjust the switches to give a midĆscale deĆ
flection of the ammeter when the transformĆ
er is energized without the field coil.
c. Close the line switch and read the ammeter.
d. Open the line switch and place the field coil
     
    around the transformer core.
 !
.
e. Apply pressure to hold the field coil against
3. The growler test method: the support and close the line switch.

12
 )
          )

f. Read the ammeter. If the ammeter deflection
is different from what it was without the coil
under test, the coil is defective.
# $&( %&%
If a complete set of coils is installed, pass a small dĆc
current through the field circuit and check the polarity
of each coil in one of the following ways.
1. Bring a compass close to pole face of coil to be
tested. If the correct coil is installed and the
proper connections are made, the south end of
the needle will point to a north field coil, or the
north end of the needle will point to a south field
coil. Refer to the connection diagram.
brush and pull the scale in a plane parallel to
the brush movement.
c. Read the scale when the pressure between
the lever and brush is reduced sufficiently to
free the strip of paper.
d. If the spring pressures on brushes are not
the same, adjust springs so that all pressurĆ
es are equal, or replace weak springs. See
individual apparatus instructions.
e. Examine pressure springs for discoloration
caused by overheating.
6. Inspect brushĆholder springs, spring tips, copĆ
per shunts, and pigtails.

2. Hold a steel bar in the magnetic field between
two adjacent poles. If the coils and connections
are correct, the bar will be attracted. If the coils
or connections are incorrect, the bar will be reĆ
pelled.
7. Examine studs and insulators for chipping,
cracking, or burning from flashover.
8. Recondition or replace defective parts. Replace
a brushĆholder if the carbonways are worn
enough to allow more than 0.020Ćinch clearĆ


 
)
 ance in thickness between the brush and the
1. Check the brushes. See individual apparatus inĆ
structions for data.
$'%)# $ '%&!"&
2. Examine brushĆholders for damage.
3. Work the brushes up and down several times in
the holders to release carbon dust or foreign
material and to insure free movement of
brushes. Do not snap the brushĆholder spring.
4. Check clearances between the bottom of the
brushĆholders and the commutator. See individĆ
ual instructions.
5. Check brushĆholder pressure springs as folĆ
lows:
(See Fig. A of Fig. 10)
a. Insert a strip of paper between the presĆ
sureĆspring lever and the brush.
b. Hook a spring scale where the presĆ
sureĆspring lever makes contact with the
carbonway.
1. Place a piece of cardboard or fiberboard of
thickness equivalent to specified clearance beĆ
tween the bottom of brushĆholder and the comĆ
mutator.
2. To adjust the traction motor brushĆholder, loosĆ
en the clamp bolts to move the holder.
3. To adjust the tractionĆgenerator brushĆholder:
a. Loosen (or remove) the bolt in the slotted ear
of the bus ring.
b. Loosen the cap screw which secures the
mycalex stud to the framehead.
4. Move the brushĆholder up or down to obtain
proper clearance and retighten bolts and
screws.
5. Remove the cardboard or fiberboard.
13
%

%
    

4. Replace stud insulation if defective. See individĆ

ual apparatus instructions.

5. Replace pressureĆarm assemblies if the copper

tips are worn halfway through or if the shunt has
been burned, broken, or frayed. Make sure the
rivets which hold the tip and shunt to the spring
are tight.

6. Replace brushes if pigtails are damaged.

!$"  #
1. Disconnect the pigtail on the old brush, lift the
brush lever, and remove the old brush.

2. Replace with the same grade of brush. Lift the

lever and insert a new brush in the carbonway.
Do not allow the lever to snap down on the
brush.

3. Secure the brush pigtail under the terminal

screw on the brushĆholder. Arrange the shunts
so they will clear the commutator risers and the
window in the brushĆholder body. Keep the
shunts away from other steel parts.

4. When new brushes are installed in generators

sand them in as follows: (See Fig. B and C of
Fig. 10)

a. Place a strip of fine sandpaper under the

FIG. 10. FIG. A ILLUSTRATES A METHOD OF
OBTAINING BRUSH PRESSURE. FIGS. B AND C
ILLUSTRATE A METHOD OF SANDING
BRUSHES. EĆ9682A.
brush, abrasive side up, and pull in the direcĆ
tion of rotation of the armature. Have normal
spring pressure on the brush.
b. Keep the sandpaper close to the commutaĆ
tor to avoid rounding the edges of the brush.
Lift the brush on the return stroke.

c. When fitting a complete set of brushes, cut a

#
!$"%!" strip of sandpaper the width of the commutaĆ
tor and long enough to lap over oneĆfourth of
1. Remove the brushĆholders and supports from its circumference.
the frame. Keep each clamp with its own supĆ
port. d. Place the sandpaper under the brushes and
rotate the armature, by hand until a good
2. Blow dry compressed air over the brushĆholder, seat is obtained. To rotate the tractionĆgenĆ
and wipe the body, carbonway, and insulator. erator armature, release the compression on
See CLEANING procedure. the diesel engine and bar the engine over.

3. File off beads or rough spots caused by flashĆ e. When more than oneĆthird of a set of
over. brushes are installed in a generator, apply a

14
 !
     !

soft, white brush seater to the commutator

while running at oneĆhalf speed (no load) unĆ
til brushes are polished (see Fig. 11).

f. Blow out dust.

 
  



1. Remove bearings from the armature. See indiĆ

vidual apparatus instructions.

2. Clean bearings. See CLEANING.

3. Inspect bearings to determine servicing reĆ

quired.

4. Dip the bearing parts in a light mineral oil

(SAEĆ10) heated to 90 C (194 F) to prevent
corrosion.

5. Repack bearings. See REPACKING BEARĆ

INGS.

6. Reassemble bearings. Do not interchange

bearing parts of different manufacturers.
7. If the bearing is not to be mounted immediately,
wrap it in an oilproof paper.
 
1. Examine the inner race for the following:
a. Flaking or cracks in the roller path. If found,
reject the bearing (see Fig. 15).
b. Heavy electrical pitting. If found, reject the
bearing (see Fig. 16).
c. Raised craters around the edges. Stone off
(do not file).
FIG. 11. SEATING BRUSHES. EĆ40565.
f. Smearing on flange and thrust collar (comĆ
mutator end). If found, look for evidence of
inadequate lubrication, or wear on other
parts caused by assembly being cocked.
2. Examine the outer race as follows:
a. Look for evidence of spinning in the housing.
If turning is severe, replace the bearing.
Bush and rebore the framehead.
b. Slide one of the rollers around the race by
hand. If the roller drags, scrap the bearing.
3. Examine cages as follows:

d. Mottled, distributed pattern of dirt denting.
Scrap the bearing, or return it to the bearing
manufacturer for examination (see Fig. 18).
e. Evidence of rubbing or turning on the shaft.
Look for loose spacers or interference of the
housing parts. If rubbing is heavy or if there
is wear on the shaft, reject the bearing.
a. Rest the bearing in vertical position and raise
and lower the cage to check clearance.
b. Rotate the rollers (or balls) to expose all surĆ
faces. Look for heavy denting. Reject bearĆ
ings if dents are found.
4. Scrap the bearing if any of the following are disĆ
covered on any of the bearing parts:

15
!
!     

FIG. 12. INNER RACE SCORED DURING

ASSEMBLY BY MOUNTING WITH COCKED OUTER
RACE AND ROLLERS (COURTESY OF S.K.F.
INDUSTRIES). EĆ1071.

FIG. 13. ABUSE OF INNER RACE FROM

OVERHEATING. DO NOT EXCEED 135 C (275 F).
 ($ %$  '% +  #'& ', (COURTESY OF S.K.F. INDUSTRIES). EĆ1070.
$&! %  

 !$$!%( "&&  '% + !%&'$ !$ !&,

$ !$$!%(  &%
 %&$'& & '$ & !($ $!$%    &
 %&!$& !$ %!& "$&% '% + !($&,
$% $ ! &  $   !'&$ $ 
  '$  %%+ %  
"% ! !& !($$%
 $   '% + ($&! % ) $%'&
 "$%%! % !$ $!!(% %    
  
 $% !$ $% "!%%+ '% + %&$,
  & %& )&  $ '$  $!(   &   "+ ! & !&!$ * $ 
%      % % !!)%



 !( & !&!$ % $ % & ) ! !  *

  %'$ && & $  !"$& & %

   $+  %'$ & $  ! & !""!%& %
&) & $      & * !,
   (' ""$&'%  %&$'&! % !$ &+" $ !$ $ ' !$ ) ' )&  $
  !' & ! '$ & &! '% 



 *
    
 *

FIG. 14. BROKEN FLANGE ON OUTER RACE

CAUSED BY STRIKING END OF SHAFT WITH
A SLEDGE. EĆ1162.

c. Check individual apparatus instructions. ReĆ

place linings if the clearance exceeds the
given value. FIG. 15. OUTER RACE FAILURE CAUSED BY
FATIGUE FLAKING. (COURTESY OF S.K.F.
2. Check radial wear of bearing linings as follows: INDUSTRIES). EĆ1072.

%)$!"( %)& #& &$&"

a. With the motor removed from axle, asĆ
semble the bearing and axle caps. Tighten
&"'
the axleĆcap bolts. 1. A centigrade thermometer.
2. A stop watch.
b. Measure the bore of linings with an inside miĆ
crometer, and measure the diameter of the 3. A Zahn viscosimeter (Cat. 5102111G3) with
axleĆbearing seat with an outside micromeĆ No. 3 cup.
ter. Subtract the axle diameter from the diĆ
4. Curve sheets for correcting viscosity reading to
ameter of the linings. If this difference exĆ
25 C:
ceeds the value given in data of individual inĆ
structions, replace bearing linings. GEĆA15B17A varnish . . . . . . . . . . . . . . . . . . . Fig. 20
GEĆA15B17B varnish . . . . . . . . . . . . . . . . . . . Fig. 21
GEĆA15B19B varnish . . . . . . . . . . . . . . . . . . . Fig. 22
     
(& '
To obtain satisfactory penetration, film building,
bonding and curing, apply varnish at correct viscosity.
GEĆ7172 varnish . . . . . . . . . . . . . . . . . . . . . . . Fig. 23
GEĆ1678 varnish . . . . . . . . . . . . . . . . . . . . . . . Fig. 24
GEĆ9700 varnish . . . . . . . . . . . . . . . . . . . . . . . Fig. 25
5. A supply of solvent. Use a highĆsolvency naphĆ
tha thinner, such as toluol (GEĆD5B11), SolvesĆ
so No. 100 (GEĆD5B30D0) or equivalent.
17
#
#  
 



FIG. 16. ELECTRICAL PITTING OF INNER RACE.

(COURTESY OF S.K.F. INDUSTRIES). EĆ1073.

FIG. 17. WORN BEARING CAUSED BY LACK OF

#

! "   
Viscosity: 34 to 52 seconds at 25 C with No. 3 Zahn
cup (275 to 450 Centipoises).
Baking Time and Temperature:
5 hours at 140 to 150 C (284 to 302 F) or 12 hours
at 120 to 130 C (248 to 266 F).
LUBRICATION. NOTE FINS ON CAGE
BETWEEN ROLLERS. EĆ1075.
Use: A slowĆdrying varnish which provides a finished
surface. Will air dry over a long period of time; it
normally must be baked. Glyptal No. 8001
meets this specification.

Use: An airĆdrying varnish for brushing over impregĆ #  ! ! "
nated insulation or metal surfaces to provide a
Viscosity: 67 to 90 seconds at 25 C with No. 3 Zahn
finished surface. Glyptal* No. 1201 meets this
cup (700 to 960 Centipoises).
specification.
Baking Time and Temperature:
# 
 ! " 7 hours at 140 to 150 C (284 to 302 F) or 18 hours
at 120 to 130 C (248 to 266 F).
Viscosity: 43 to 57 seconds at 25 C with No. 3 Zahn
cup (350 to 500 Centipoises). Use: A penetrating varnish for impregnating winding
insulation. lt must be baked to cure. Glyptal Nos.
Baking Time and Temperature: 2480 and 7170 meet this specification.
5 hours at 140 to 150 C (284 to 302 F) or 12 hours
at 120 to 130 C (248 to 266 F). * Reg. tradeĆmark of GE.

18
 (
     (

FIG. 18. DIRT DENTING OF INNER RACE WAS

PROBABLY CAUSED BY FLAKED OUTER RACE.
EĆ1076.
FIG. 19. BRINELLING OF INNER BEARING RACE.
HEAVY LINES PROBABLY
INDICATE TRUE BRINELLING. EĆ1161.
 #

 !$ $" %
Use: A penetrating varnish for randomĆwound armaĆ
Viscosity: 42 to 50 seconds at 25 C with No. 3 Zahn ture and stator windings. It must be baked to
cup (400 to 500 Centipoises). cure.

Baking Time and Temperature:

 !$ $" %
7 hours at 140 to 150 C (284 to 302 F) or 18 hours
at 120 to 130 C (248 to 266 F).
Use: A penetrating varnish for impregnating winding
insulation. It must be baked to cure.
 # 
 !$ $" %
Viscosity: 60 to 80 seconds at 25 C with No. 3 Zahn
cup (620 to 850 Centipoises).
Baking Time and Temperature:
7 hours at 140 to 150 C (284 to 302 F) or 18 hours
at 120 to 130 C (248 to 266 F).
 # 
Viscosity: 43 to 57 seconds at 25 C with No. 3 Zahn
cup (350 to 500 Centipoises).
Baking Time and Temperature:
7 hours at 140 to 150 C (284 to 302 F) or 18 hours
at 120 to 130 C (248 to 266 F).
Use: A penetrating varnish for randomĆwound armaĆ
ture and stator windings. It must be baked to
cure.
$#&$ #$  ' " $" %
1. Mix materials thoroughly and allow to settle for a
few minutes to eliminate air bubbles.
19



   
 


TEMPERATUREĆVISCOSITY CURVES FOR TEMPERATUREĆVISCOSITY CURVES FOR

GEĆA15B17A VARNISH. GEĆA15B17B VARNISH

TO CORRECT MEASURED VISCOSITY TO CORRECT MEASURED VISCOSITY AT 25 C.

AT 25 C.
EXAMPLE: IF THE STOPĆWATCH READING IS 35
EXAMPLE: IF THE STOPĆWATCH READING SECONDS, AND THE ENAMEL TEMPERATURE IS
IS 35 SECONDS, AND THE VARNISH TEMĆ 32 C, THE VISCOSITY AT 25 C IS
PERATURE IS 32 C, THE VISCOSITY AT 25 BETWEEN 50 AND 55 SECONDS OR ABOUT
VISCOSITY - SECONDS ON NO. 3 ZAHN CUP

C IS BETWEEN 45 AND 50 SECONDS OR 51 SECONDS.

ABOUT 49 SECONDS.

VISCOSITY - SECONDS ON NO. 3 ZAHN CUP

RECOMMENDED VISCOSITY 43 TO 57
RECOMMENDED VISCOSITY 34 TO 52 SECONDS AT 25 C. (BARREL VISCOSITY)
SECONDS AT 25 C. (BARREL VISCOSITY)

TEMPERATURE OF VARNISH -
C
FIG. 20. TEMPERATUREĆVISCOSITY CURVES FOR
GEĆA15B17A VARNISH. EĆ40566.
2. Suspend a thermometer in the varnish.
3. Immerse viscosimeter cup till the rim is just
beneath the varnish surface. Let it remain in the
material for about a minute to assume the same
temperature.
4. Raise the cup quickly, holding the ring in the end
of the handle, and start the stop watch at the inĆ
stant the cup leaves the surface of the liquid.
5. Stop the watch at the instant the draining colĆ
umn breaks from the cup (starts to drip).
TEMPERATURE OF VARNISH -
C
FIG. 21. TEMPERATUREĆVISCOSITY CURVES FOR
GEĆA15B17B VARNISH. EĆ3852B.
6. The number of seconds measured is the viscosĆ
ity at the temperature of the material.
7. Refer to the applicable curve sheet to correct
the viscosity as measured, to the viscosity at 25
C.
8. If the viscosity, corrected to 25 C, does not corĆ
respond to the recommended viscosity for 25 C:
a. Add solvent to decrease the viscosity.
b. Add new stock to increase the viscosity.

20
  
    
  

TEMPERATUREĆVISCOSITY CURVES FOR TEMPERATUREĆVISCOSITY CURVES FOR

GEĆA15B19B CLEAR VARNISH GEĆ7172 CLEAR VARNISH

TO CORRECT MEASURED VISCOSITY AT TO CORRECT MEASURED VISCOSITY

25 C. AT 25 C.

EXAMPLE: IF THE STOPĆWATCH READING EXAMPLE: IF THE STOPĆWATCH READING

IS 30 SECONDS, AND THE VARNISH TEMĆ IS 30 SECONDS, AND THE VARNISH TEMĆ
PERATURE IS 32 C, THE VISCOSITY AT 25 PERATURE IS 39 C, THE VISCOSITY AT 25
C IS C IS BETWEEN 55 AND 60

VISCOSITY - SECONDS ON NO. 3 ZAHN CUP

BETWEEN 40 AND 45 SECONDS OR SECONDS OR ABOUT 58 SECONDS.
VISCOSITY - SECONDS ON NO. 3 ZAHN CUP

ABOUT 42 SECONDS.
RECOMMENDED VISCOSITY 42 TO 50
RECOMMENDED VISCOSITY 67 TO 90 SECONDS AT 25 C. (NOT BARREL
SECONDS AT 25 C. (NOT BARREL VISCOSITY)
VISCOSITY)

TEMPERATURE OF VARNISH -
C
TEMPERATURE OF VARNISH -
C

FIG. 22. TEMPERATUREĆVISCOSITY CURVES FOR FIG. 23. TEMPERATUREĆVISCOSITY CURVES FOR
GEĆA15B19B VARNISH. EĆ3851A. GEĆ7172 CLEAR VARNISH. EĆ7058.


 
To test for percent of solids use a small, shallow,

  clean container and proceed as follows:
  &"   %$ !# (%   # %#
 #   % !# (%  !#+ 1. Weigh the container.
#) ""  #
2. Pour a small quantity of varnish (15 to 20 grams)
  $&# $%#) &"$ !# $ $  % '# $
into the container and reweigh.
! !% "#!!  % #   % ( %+
   # 
3. Place the container and its contents in an oven
  ! %! ! '# $ !# &$  % and bake four to six hours at 125 C (257 F).
&$% !%  $"# ) !# #&#)  * 
$ !&## ! !% &$ 4. Remove from the oven and weigh.
 #!)  "# % ! $!$ ! +
% % ! % '# $ %# !##%  % '$+ 5. Subtract the weight of the container from the
!$%)
! $$% % #$ ! "# % ! weight of the unbaked varnish.
$!$  %$ % $%#% !  
6. Subtract the weight of the container from the
weight of the baked varnish.

21

     


TEMPERATUREĆVISCOSITY CURVES FOR TEMPERATUREĆVISCOSITY CURVES

NO. 1678 VARNISH FOR NO. 9700 VARNISH

TO CORRECT MEASURED VISCOSITY TO CORRECT MEASURED VISCOSITY

AT 25 C. AT 25 C.

EXAMPLE: IF THE STOPĆWATCH READING EXAMPLE: IF THE STOPĆWATCH READING

IS 25 SECONDS, AND THE VARNISH TEMĆ IS 25 SECONDS, AND THE VARNISH TEMĆ
PERATURE IS 39 C, THE VISCOSITY AT 25 PERATURE IS 32 C, THE VISCOSITY AT 25
C IS BETWEEN 45 AND 50 C IS BETWEEN 30 AND 35
SECONDS OR ABOUT 47 SECONDS. SECONDS OR ABOUT 33 SECONDS.
VISCOSITY - SECONDS ON NO. 3 ZAHN CUP

VISCOSITY - SECONDS ON NO. 3 ZAHN CUP

RECOMMENDED VISCOSITY 60 TO 80 RECOMMENDED VISCOSITY 43 TO 57
SECONDS AT 25 C. (BARREL VISCOSITY) SECONDS AT 25 C.

TEMPERATURE OF VARNISH -
C
TEMPERATURE OF VARNISH -
C

FIG. 25. TEMPERATUREĆVISCOSITY CURVES FOR

FIG. 24. TEMPERATUREĆVISCOSITY CURVES FOR GEĆ9700 CLEAR VARNISH. EĆ3861.
GEĆ1678 CLEAR VARNISH. EĆ40567.

5. Run the apparatus for five minutes at half speed,

then increase to full speed and run for two
% of Solids = Weight of baked varnish X 100
hours. Note bearing temperatures. Do not allow
Weight of unbaked varnish
them to exceed 70 C (158 F). Continue to run the

  
1. Compare connections with the connection diaĆ
gram.
2. Check polarity of the field coils. See POLARITY
TESTS.
3. Be sure that no foreign matter remains in the
machine, and that there are no loose brushes or
other obstructions on the commutator.
4. Connect the apparatus, except traction generaĆ
tors, to a source of power such as a dĆc arcweldĆ
ing generator and run it as a motor.
apparatus until temperatures remain constant
for 30 minutes.
6. Measure vibration of apparatus with a VibraĆ
meter". Rebalance the armature or replace
bearings if vibration exceeds 0.004 inch.
7. Check the commutator for roughness. Be sure
brushes are riding properly. Commutator
runĆout must not exceed 0.001 inch.
8. Listen for noisy bearings with a listening rod.
9. Measure impedance of the field coils. See IMĆ
PEDANCE TEST.

22
 
  
 
 
    


 
 
     
 

GEĆA15B17A GEĆA15B17B GEĆA15B19B GEĆ7172 GEĆ1678 GEĆ9700

Alkyd
Alkyd Alkyd Alkyd Phenolic Phenolic Phenolic
Type Resin Resin Resin Resin Resin
Resin
Solids Content, % Min. 58 56 50 50 60 50

Viscosity at 25 C, c.p.
Minimum 275 625 700 700 700 375

Drying time at 21 C:
Tack free, Maximum
Hours 1 2.5 - - - -
Thru Dry, Maximum
Hours 8 10 - - - -

Drying time at 150 C:

Cure, Maximum Hours 0.5 0.5 4 4 2 2

Dielectric V/mil:
Minimum, dry 1000 1000 1500 1500 - -
Average, dry 1500 1600 2000 2000 1910 2200
Minimum after 24 hours
in water 300 300 750 750 - -
Average after 24 hours
in water 300 688 - - 1240 1200
Minimum after 24 hours
in 2% NaCI 200 200 500 500 - -

Immerslon in oil
Room Temperature, 24
Hours - effect None None None None None None

Immersion in 10% NaCl

Room Temperature, 24
Hours - softening None None None None None None

For additional properties of these varnishes and/or copies of Specification sheets, consult your nearest GE
representative.

23
)
)
    


        
    !    ! 
        
 "  

 $!%#"$&&"!
(%& %

 %&  "

$ !!%('!  





 


 MI31100017A
GEI85167A

COMMUTATOR MAINTENANCE

CONTENTS know what to do, you can often correct the trouble be
fore it becomes serious.
Page
The more you know about a commutator, the better
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
you can maintain it.
FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
COMMUTATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 FUNCTION
CONSTRUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
PROCESSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 A commutator has three functions:
COMMUTATOR SURFACE CONDITIONS . . . . . . . 4
SURFACE FILM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 1. It provides the required sliding electric contact
COLOR PATTERN . . . . . . . . . . . . . . . . . . . . . . . . . . 5 between the fixed brushes and the moving ar
MARKING, ETCHING, AND FLAT SPOTS . . . . . . 6 mature to remove or apply electrical energy to
THREADING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 the machine.
COPPER DRAG . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
BANDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 2. It acts as a reversing switch. As the ends of the
ECCENTRICITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 armature coils pass the brush positions, the
SURFACE BREAKS . . . . . . . . . . . . . . . . . . . . . . . . 10 commutator switches them from one circuit to
HIGH BARS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 another where the current is flowing in the oppo
HIGH MICA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
site direction. Thus all the coils have current
FLASHOVER DAMAGE . . . . . . . . . . . . . . . . . . . . . 12
flowing through them in the proper direction at
OTHER FACTORS AFFECTING COMMUTATION 12
COMMUTATOR INSULATION . . . . . . . . . . . . . . . . . 13 all times.
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 3. It also brings to the brush surface the voltage of
RESURFACING THE COMMUTATOR . . . . . . . . . . 14
each armature coil in the circuit. These voltages
POLISHING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
add up bar by bar between brushes. As a result,
STONING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
TURNING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 the total operating voltage of the machine ap
UNDERCUTTING . . . . . . . . . . . . . . . . . . . . . . . . . . 15 pears at the brushes.
SLOT RAKING AND BRUSHING . . . . . . . . . . . . . 16
AIR CURING THE COMMUTATOR . . . . . . . . . . . . 16 COMMUTATION
SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . 17
Commutation is the successful reversal of current in
a coil being short circuited by a brush.
INTRODUCTION The current flow through the brushes and armature
The commutator is a vital part of every DC motor windings of a DC machine normally takes several paths
and generator; therefore, it deserves the very best of through the armature windings as it enters from the
care. The fact that a commutator usually shows signs commutator. After flowing through the windings, the
of distress before trouble actually occurs, is big help to paths again join and it leaves through the outgoing
the maintainer. If you can recognize these signs and brush.

These instructions do not purport to cover all details or variations in equipment nor to provide for every possible contingency to be met in connection with installation, operation, or mainte
nance. Should further information be desired or should particular problems arise which are not covered sufficiently for the user's purposes, the matter should be referred to the General
Electric Company. Any applicable Federal, State or local regulations or company safety or operating rules must take precedence over any instructions given in this material. GE has no
obligation to keep the material up to date after the original publication.

THERE ARE NO WARRANTIES OF ACCURACY, MERCHANTABILITY OR FITNESS FOR PARTICULAR PURPOSE.

Verify numbers for parts, tools, or material by using the Renewal Parts or Tool Catalogs, or contact your
General Electric representative for assistance.
Do not order from this publication.
MI31100017A
GEI85167A, COMMUTATOR MAINTENANCE
FIG. 1. SKETCH OF ARMATURE SHOWING
DIRECTION OF CURRENT FLOW THROUGH THE
COILS. POLARITY OF A GENERATOR IS SHOWN.
E8686.
As each coil passes under the brush (Fig. 1) the cur
rent flows in one direction when on one side of the
brush and in the opposite direction when on the other
side; so the current must go to zero, then reverse in the
split second it takes for the coil to pass under the brush.
Note each brush is wide enough to bridge two adjacent
commutator bars and short circuit the armature coil for
an instant. This is commutation.
What happens if the current doesn't reverse in
time? The coil will come out from under the brush with
the current still flowing in the initial direction. The meet
FIG. 2. RELATIVE POSITIONS OF MAIN POLES,
COMMUTATING POLES, AND SHORT
CIRCUITED COILS IN WHICH CURRENT IS BEING
REVERSED. E8687.
2
ing point with the current in the other path (called the
neutral point") will no longer be under the brush. This
moving of the neutral point" crowds the current to one
edge of the brush. Then it breaks out over the surface
of the commutator in a spark to reach this shifted point.
These machines operate over a wide range of load
current, and the greater the current, the harder it is to
achieve a complete reversal as the coil races under the
brush. Thus most large DC machines have interpoles
(or commutating poles) to speed up this current rever
sal and keep the neutral point" under the brush. These
are smaller poles located between the main poles in
the generator or motor frame (Fig. 2). The polarity is the
same as the next pole in the direction of rotation for a
generator and the same as the last preceding pole for a
motor. They do no work outside of helping with the
commutating job. The magnetism of these poles builds
up a voltage in the armature coils as they pass through
the zone covered by brush contact. This voltage
speeds up the current reversal to complete it before the
coil leaves the brush contact.
These poles are designed to do a good commutat
ing job up to, and even beyond, full load. When, howev
er, a very sudden overpowering current flows through
the windings, the magnetism in the iron cannot build
up quickly enough. It is like suddenly turning on a gar
den hose  it takes a few seconds to fill before water
comes out the nozzle. This means there is not enough
voltage to reverse the current in time and sparking re
sults. Besides, you can force only so much magnetism
through a piece of iron. Then it becomes filled up or
saturated." It is like trying to force more water through
the hose than it can handle. Hence, there is a limit to the
help the poles can give in reversing the current in the
coil. When the current gets so heavy that this help is not
enough, you have more load than the machine can
handle and sparking results.
Equalizer Coils
Multiple or Lap Winding
Since the flux per pole is never exactly the same for
all poles, the voltage in the parallel circuits (the number
of such circuits depending on the number of poles) will
not all be equal. This will result in circulating currents,
since the circuits are in parallel. Even a small voltage
 MI31100017A
COMMUTATOR MAINTENANCE, GEI85167A

FIG. 3. SCHEMATIC DIAGRAM OF MULTIPLE OR LAP ARMATURE WINDING IN A

6POLE MACHINE. E8688A.

change would cause large circulating currents, be CONSTRUCTION

cause resistance is relatively low (Fig. 3).
A commutator is formed of alternate copper seg
ments and mica plates (Fig. 4). Copper segments are
If this circulating current were allowed to pass often called bars" so hereafter, in this publication, we
through the commutator into the brushes and com will use the term bar instead of segment.
plete its circuit through the brushholder connecting
bus rings, it would upset commutation and result in The mica plates physically separate and electrically
sparking at the brushes. To avoid this, equalizer coils insulate the bars and provide arch pressure essential
are used to connect commutator segments of the to commutator stability. The plates are undercut below
same potential (i.e., segments at double the brush the commutator surface to prevent interference with
spacing intervals), Fig. 3. The circulating current then
passes through these equalizer coils instead of
through the commutator, into the brushes. This circu
lating current produces a magnetomotive force in such
a direction that it tends to bring the fluxes of several
poles into equality. Hence, the net circulating current is
reduced to a relatively small value.

Series or Wave Winding

In this type of winding there are two parallel paths

through the armature, each path consisting of onehalf
of all of the armature conductors in series with each
other. The voltage generated in either half of this paral
lel circuit adds up to the terminal voltage of the ma
chine.

With this type of winding, no equalizer coils are re FIG. 4. CUTAWAY SECTION OF THE
quired. COMMUTATOR. E5018.

3
MI31100017A
GEI85167A, COMMUTATOR MAINTENANCE
FIG. 5. ARCH-BOUND COMMUTATOR ASSEMBLY.
E-3059B.
the sliding action of the brushes on the surface of the
commutator.
The bars are wedge shaped and form a cylinder
when assembled. Each bar has a riser at one end to
make armature coil connections.
The bars are held in position by the clamping action
of a steel cap bolted to a steel shell (Fig. 5).
Mica cones, contoured to fit between the shell and
cap, insulate the bars from ground (armature).
A Teflon* creepage band, applied on the exposed
cone insulation, protects the mica from damage and
presents a smooth creepagesurface that is easy to
keep clean.
ArchBound Commutator
An archbound commutator exerts pressure on the
30degree surface of the copper segments only, Fig. 5.
This pressure is supported by the archpressure of the
segments pressing against each other around the
complete periphery, as the name archbound" im
plies. An actual clearance (usually 1/16 in.) exists be
*Product of E.I. DuPont de Nemours & Co., Inc.
4
tween the 3 or 6 degree surface of the copper seg
ments and the mica cone covering the outer slope of
the commutator cap. The clearance opening is sealed
to prevent the entrance of carbon dust which could
short circuit or ground the bars.
The archbound type of construction produces a
commutator which is less subject to roughening of the
brush surface from heat shock. Also, it is less sensitive
to machining tolerances and mica shrinkagevari
ations, since it does not require the critical balance of
pressure between the 3 and 30 degree surface as does
a Veebound" commutator.
PROCESSING
Long term engineering and manufacturing experi
ence is applied to achieve maximum commutator sta
bility. This results in:
1. A commutator surface that will not roughen at
high speed.
2. A commutator surface that will not roughen
when heated (i.e., during high current standing
starts) or, if smooth while hot, will not roughen
when cooled.
3. A commutator surface that will not roughen due
to movement of the bars after having been in
service for a period of time.
To produce a stable commutator, a series of high
temperature bakings and capscrew tightenings are
performed on the fixtureheld cylinder of bars and mica
plates before they are machined and also after the
commutator has been completely assembled. The
baking temperatures exceed any the commutator
would normally encounter in service.
A large number of transportation commutators are
seasoned" in spin stands, after they have been as
sembled on armatures and the armature coils applied.
In the spin stands, the commutators are subjected to
repeated cycles of heating and cooling while running at
speeds approximately 20 percent above maximum op
erating speed. A common cycle is to heat the commu
tator to 160 C in one hour, hold this temperature for 1/2
hour, and cool to room temperature in 1/2 hour  all at
high speed. This cycle is repeated a number of times to
obtain the desired results.

COMMUTATOR
SURFACE CONDITIONS
A commutator cannot work properly unless the
brushes make good electrical contact. This requires a
smooth, polished, cylindrical surface that runs true
with its center. When you realize the maximum speed at
which this surface must slide under the brushes, you
can see why it must be as smooth and true as possible.
Remember a commutator is not a solid piece. It is
made up of many copper bars and mica plates
clamped between steel parts. These materials react
differently to temperature changes (expanding and
contracting at different rates). This establishes forces
which tend to shift the parts. Also, the parts tend to shift
during operation because of centrifugal action. In spite
of all that is done in an attempt to maintain a perfect
commutator surface, small variations are usually pres
ent. Brushes, forced against the commutator surface
by spring pressure, will follow these variations if they
are not too sudden.
It is the maintainer's job to spot a commutator sur
face heading for trouble and correct it before failure oc
curs. A knowledge of various surface conditions and
how they affect commutation and current collection will
be helpful.
SURFACE FILM
The successful operation of all DC machines de
pends on maintaining a proper film on the surface of
the commutator. This film of carbon, graphite, copper
oxide and water vapor is deposited on the commutator
surface by electrochemical action. It is formed by the
wiping action of the brush against the commutator and
by the normal current flow between the brush and the
commutator.
The fact that a commutator surface is never abso
lutely smooth, although it may feel so to the touch and
look so to the eye, enables the film to stick. Normally,
on a new or reconditioned commutator, the brush be
gins to establish its characteristic film as soon as cur
rent flows. It may take several hours or several days to
establish a good film  after which the main job is to
maintain this film.
MI31100017A
COMMUTATOR MAINTENANCE, GEI85167A
Temperature, atmosphere and grade of brush used
all affect this film. If the film is damaged electrically or
mechanically, both brush and commutator wear is ac
celerated.
A sliding contact such as a carbon brush is very
sensitive to even the slightest variation in the atmo
sphere. Acid or base contaminations, dust, and oils
react with the brush and commutator surface to cause
disturbing conditions. Even normal changes in humid
ity cause noticeable changes in contact voltage drop
and friction of a brush. These variations may result in
the formation of irregular patterns on the commutator
surface.
Chemical contamination probably causes the
greatest disturbance, since formation of materials oth
er than copper oxide is usually harmful. Abrasive dust
wears away the film, while other types of suspended
particles react with the vaporized copper to form non
conductive films. Many organic materials are just as
harmful as chemical contaminants.
Oil vapors have a decided effect on film condition.
Not only does the oil introduce an insulating surface, it
also prevents bonding of film on the commutator and
causes a torn or mottled film surface. It will also pro
mote rapid metal transfer and, eventually, threading.
Some types of brushes establish a heavier film than
others depending on the brush grade. Some grades
require greater current densities (amperes per square
inch average current) to establish and maintain a satis
factory film than do other grades.
The machine manufacturer selects and recom
mends a brush grade suited to the application of the
machine. Use the recommended brush grade. Do not
mix or change the brush grade as it could seriously af
fect commutation, surface film and brush life.
The importance of maintaining a proper commuta
tor surface film cannot be overemphasized. With this
film established and properly maintained, good brush
performance (reduced brush and commutator wear)
and satisfactory commutation (no destructive spark
ing) is assured. Changes in color from copper to deep
brown or chocolate should give no cause for worry, as
long as the surface is smooth and has a polished
glossy appearance (Fig. 6).
5
MI31100017A
GEI85167A, COMMUTATOR MAINTENANCE
FIG. 6. GOOD COMMUTATOR FILM OF UNIFORM
COLOR. E8761A.
COLOR PATTERN
This term indicates only that the color of the com
mutator bars is not uniform and a definite pattern ex
ists. The pattern is almost always related to the ar
rangement of coils in the armature slots. In itself, this
FIG. 7. ONE LIGHTTWO DARK, 3 COIL PER SLOT
COLOR PATTERN. E8762A.
6
FIG. 8. ONE DARKTWO LIGHT, 3 COIL PER SLOT
COLOR PATTERN. E8763.
condition is not a sign of damage. The color pattern
may show up in several sequences (Figs. 7 and 8). As
long as there is a definite pattern around the whole
commutator, do not be concerned.
A check for surface damage should be made at
scheduled commutator inspection periods. If no dam
age exists, no further action is required.
MARKING, ETCHING, AND
FLAT SPOTS
The following conditions indicate discoloration and/
or etching of commutator bars  but in varying degrees.
Possible causes of etching and discoloration include:
1. Excessive load on the machine.
2. Electrical adjustment off; such as, wrong shims
behind commutating poles or wrong interpole
gap.
3. Wrong brush grade.
4. Uneven or rough commutator surface.
5. Contaminated atmosphere.
6. Incorrect brush spacing.
7. Incorrect brush shift.
The best way to overcome these conditions is to de
termine the cause and make the necessary correc
tions. If damage has not progressed too far, it may clear
 MI31100017A
COMMUTATOR MAINTENANCE, GEI85167A

FIG. 9. COMMUTATOR FILM REMOVED WITH A

PENCIL ERASER TO SHOW A SMOOTH COPPER
SURFACE UNDERNEATH. E8764. FIG. 11. IRREGULAR FILM AND ETCHING CAUSED
BY A ROUGH COMMUTATOR. E8766.

The term burned bars" is sometimes used to indi

itself once the cause has been eliminated. If it is deter cate bar surface etching. This merely represents an ad
mined that some resurfacing of the commutator is nec vanced stage of etching.
essary, it should be done sparingly.
Bar Corner Etching
Marking When this condition prevails, the corner of the bar is
eroded, leaving a chamfered corner but little or no evi
This condition appears as an opaque darkened sur dence of marking or bar surface etching.
face or black deposit on the bars, usually at their trailing
edge, with no etching or corrosion of copper under Bar corner etching may best be seen by holding a
neath. light source at an angle which will reflect light from a
chamfered corner to the eye.
Check for this condition quickly by using a common
pencil eraser to remove the deposit; then examine the
copper surface for roughness or pitting. If none is seen,
the condition is marking, which can readily be removed
with a canvas cloth (Fig. 9).

Bar Surface Etching

This condition gives the appearance of severe

marking, and a pencil eraser uncovers pitting, eroded,
or burned bar surfaces. Such a condition results from
arcing between the brush and the copper commutator FIG. 10. HEAVY ETCHING ON A 2COIL PER SLOT
bars and the etching is usually visible with the naked COMMUTATOR. E8765A.
eye when the marking is removed (Figs. 10 and 11).

7
MI31100017A
GEI85167A, COMMUTATOR MAINTENANCE

Flat Spots
If etching is not corrected and progresses too far,
flat spots will develop. Flat spots may also develop from
a mechanical disturbance, such as the vibration from a
defective bearing. As a rule, however, flat spots result
from failure to correct some faulty condition which is
first indicated by burned bars (Fig. 12).

THREADING
Threading is a commutatorsurface condition that
shows as circumferential grooves on the commutator.
Threading is the result of abrasive or electrochemical
action of the brushes. FIG. 13. HEAVY THREADING OF COMMUTATOR.
E8768A.
In light threading, grooves may just barely be ap
parent where the surface film or color is disturbed or
different. In heavy threading, a rippled surface can be
felt if you rub a fingernail along the surface of a bar
(Figs. 13 and 14).

The brush faces wear to fit these grooves. When the

commutator shifts due to armature endplay, the
brushes are lifted out of the grooves. Then contact be
tween the brush and the commutator is disturbed,
sparking occurs, and commutation is disrupted.

FIG. 14. ILLUSTRATION OF THREADING OF

COMMUTATOR SURFACE. E5023.

Possible causes of threading include:

1. Low currentdensity in the brush (machine is not

heavily loaded).

2. Abrasive dirt or other foreign material imbedded

in the face of the brush.

3. Mica flakes or copper imbedded in the brush

FIG. 12. FLAT SPOT ON A COMMUTATOR THAT face.
ALSO SHOWS FLASHOVER DAMAGE. E8767.
4. Wrong brush grade.

8
 MI31100017A
COMMUTATOR MAINTENANCE, GEI85167A

FIG. 15. COPPER DRAG ON TRAILING EDGE OF

COMMUTATOR BARS. E8769A. FIG. 17. EXAMPLE OF BANDING. E8771.

6. Low current density.

Determine the cause of the threading and resurface
by grinding (with a rigidly mounted grinding fixture as
listed in the Tool Catalog) or by turning on a lathe.
COPPER DRAG
A temporary solution to copper drag is to clean the
commutator occasionally with a light brushseater
stone. If drag has progressed too far, the slots must be
raked and cleaned.

Under certain conditions copper is dragged over BANDING

the trailing edges of the commutator bars and has the
appearance of small metal flakes or feathers. Copper
drag is caused by particles of copper, copper oxide
and contaminates that do not bond firmly to the surface
of the commutator. As the commutator rotates, the
brushes shove small flakes of this material toward or
into the commutator slots. This decreases the distance
between the bars. An arc formed at any brush can then
be more easily carried over to an adjacent brush result
ing in a flashover.
Banding is a surface defect in the form of bands
around the commutator in which the surface film has
been partially or completely removed. These bands
may be quite narrow (not to be confused with thread
ing) or they may extend over a sizeable percentage of
the brush path. See Fig. 17 for example of banding.
Possible causes of banding include:

Copper drag should not be confused with barcorn

er etching (Figs. 15 and 16).

Possible causes of copper drag include:

1. Contaminated atmosphere.

2. Copper imbedded in brush face.

3. Hard spot in brush.

4. Wrong brush grade.

FIG. 16. ILLUSTRATION OF COPPER DRAG.
5. Excessive vibration. E8770.

9
MI31100017A
GEI85167A, COMMUTATOR MAINTENANCE
1. Brush film too heavy (film tears from surface).
2. One brush is the wrong grade.
3. Hard spot in a brush.
Banding can be corrected by hand stoning after the
cause has been eliminated.
ECCENTRICITY
Even though a commutator surface is smooth, it
can be running off center. This is a common fault and is
usually the easiest of all surface variations for the
brushes to follow. They simply rise and fall in the hold
ers with each revolution. However, as speed goes up,
this eccentric motion becomes faster. Finally, the
brushes begin to break contact and gradually burn the
commutator surface. As this continues, the burning
causes still further surface destruction (Fig. 18).
Possible causes of eccentricity include:
1. Bent shaft.
2. Bearings not running true.
3. Commutator machined on bad shaft centers.
FIG. 18. EXAMPLE OF ECCENTRIC COMMUTATOR.
(EXAGGERATED FOR PURPOSES OF
ILLUSTRATION). E8773A.
10
4. Distortion caused by wide temperature
changes and high speed.
5. An offset coupling in single bearing traction
genrators.
Determine the cause of eccentricity and resurface
the commutator using a rigidly mounted grinding fix
ture. Eccentricity cannot be corrected by hand stoning.
If the armature is out of the frame, turn the commu
tator in a lathe (on its own bearings if possible). If the
commutator is machined on its shaft centers, the com
mutatorend bearingfit should run within 0.001 in. TIR
to the shaft centers. Prior to machining, scrape the
shaft centers, if necessary, to meet this tolerance re
quirement.
SURFACE BREAKS
Sometimes a sharp step occurs on a commutator
surface. This may be caused by a bump or blow to the
commutator. Though the change in surface level may
be very small, not even a heavy spring load will keep
the brush in contact with the depressed bars. The
brush may skijump" from the higher level or, if rotation
is reversed, the step strikes the brushes and kicks"
them away from the surface. This causes sparking, fol
lowed by electrical erosion and flat spots on the surface
of the commutator. At high speed, this kick" may be
hard enough to shatter the brushes (Fig. 19).
Possible causes of surface breaks include:
Bumping of commutator surface during handling or
striking commutator with a heavy tool, etc.
Resurface the commutator with a rigidly mounted
grinding fixture to remove the surface breaks.
HIGH BARS
If a motor armature does not rotate while power is
applied, the commutator bars under the brushes will
overheat and expand. Expansion will cause these bars
to rise above the adjacent bars. When the armature ro
tates, the high bars kick" the brushes which, in turn,
arc and burn the commutator surface. If this condition
is not corrected, the brushes may shatter and a
flashover could occur (Figs. 20 and 21).
In severe cases, bar temperature may rise high
enough to anneal the copper and destroy the binder in
 MI31100017A
COMMUTATOR MAINTENANCE, GEI85167A

FIG. 21. EFFECT OF HIGH BARS ON BRUSHES.

E5021A.
FIG. 19. EFFECTS OF DEPRESSED BARS AND
Annealed bars can be detected with a scleroscope
REVERSAL OF ROTATION. E8774.
or some equivalent means. Sometimes they can be
spotted by discoloration of the barends outside the
brush track.

HIGH MICA
High mica refers to the height relationship between
the surface of the mica plate and the surface of the

MICA PROPERLY UNDERCUT

HIGH MICA - COPPER WORN DOWN

FIG. 20. EXAMPLE OF A SOFT COMMUTATOR

BAR WHICH HAS LIFTED AT HIGH SPEED.
E5022.
the mica plates. When this happens, flakes of mica will
shift from the pressure areas and reduce the clamping
FEATHER EDGE MICA - INCORRECTLY CUT
action on the bars. Annealed bars wear differently than
normal bars and, being loose, they will lift at high arma
FIG. 22. HIGH OR FEATHEREDGE MICA. E8776.
ture speed.

11
MI31100017A
GEI85167A, COMMUTATOR MAINTENANCE

commutator bars (see Fig. 22A for correct relation

ship).

In normal use, the surface of the commutator is

gradually worn down. As the copper is worn away, the
depth of the undercut (slots) is reduced until the edges
of the mica plates are even with (or slightly higher than)
the surface of the commutator (Fig. 22B). At this point,
the mica is called high mica."

High mica can be the result of either normal electro

mechanical wear, or failure to undercut the mica after
resurfacing operations.

Feather edge mica results from the incorrect under

cutting of high mica (Fig. 22C) which leaves feather
edges of mica level with the commutator surface.

Either form of high mica disrupts the process of

commutation. This, in turn, increases wear on the com
mutator bars and the brushes . . . to expose more mica .
. . to further disrupt commutation.

FLASHOVER DAMAGE
The commutator defects previously mentioned are
similar to a crack in the highway pavement. At first the
break is hardly noticeable, but if not attended to, be
comes progressively worse until the road must be
closed.
Likewise, a commutator does not fail suddenly. Like
the pavement, it gives indications of future trouble in
time for most trouble to be prevented. To the trained ob
server, the commutator surfacedefects previously
mentioned are cracks in the pavement" that must not
be allowed to cause the machine to fail.
Any condition or defect which causes arcing on the
surface of the commutator must be regarded as a po
tential cause for a flashover. When arcing becomes se
vere enough, the surrounding air changes into a con
ductive gas and allows power to spillover between the
brushes in a flashover. A flashover is the commutator's
final protest against neglect and abuse. Evidence that
a machine has flashed over will be found in the form of
copper splatter on the surface and ends of the commu
tator bars, on the brushholders and nearby insulation
and on the frame as shown on Fig. 23.
FIG. 23. EQUIPMENT BADLY DAMAGED BY
FLASHOVER. E18333.
If a flashover occurs, clean the commutator, the Te
flon creepage band, and the brushholders. Examine
these parts for damage and check the condition of the
brush faces. Repair or replace damaged parts as nec
essary.
OTHER FACTORS
AFFECTING COMMUTATION
We have already seen that the second function of a
commutator is to act as a reversing switch. Just as me
chanical defects on the commutator surface interfere
with proper brush contact, so electrical defects in the
machine will interfere with proper switching action.
Some of the more common electrical defects are:
1. Brushes not located on neutral point.
2. Defects in either the armature or the field wind
ings. The defects may be shortcircuited turns,
grounds, open circuits, or high resistance con
nections.
3. Reversed main or commutatingfield coils.

12
 MI31100017A
COMMUTATOR MAINTENANCE, GEI85167A

4. Use of improper shims under pole pieces.

5. Wrong use of magnetic and nonmagnetic pole

piece bolts.

6. Nonmagnetic instead of magnetic bands, or

vice versa.

All these defects will cause sparking at the brushes

and may result in overheating. You are most likely to
find them after a hasty emergency repair job on the
equipment.

Anything that breaks the connection between a

commutator riser and its armature coil will affect com
mutation.

For Soldered Coil Leads

A break will occur when the commutator becomes
hot enough to melt the solder and allow the ends of the
coils to lift out of the riser slot. Such heating may be
FIG. 24. AN EXAMPLE OF MOLTEN SOLDER
caused by overloads or lack of cooling air. Hence, sol
ALLOWING THE LEADS TO LIFT. THE ARMATURE
der throwing warns the maintainer to check blowers, COILS HAVE ALSO BEEN SHORTCIRCUITED BY
belts, air ducts and covers, to be sure the machine is SOLDER COLLECTING UNDER THE INSULATION.
getting enough cooling air. Look for solder spatter on E5025.
the fieldcoil connections, the frame, etc.

A coil connection not properly soldered, or one that
has thrown solder, may oxidize rather than lift out of the
risers. When this happens, local heating will cause a
blackened or burned area on the riser at the poor con
nection. Look for discolored risers when making in
spections.
Molten solder can shortcircuit the armature coils by
collecting under the insulation. Molten solder can also
allow a coil to open up to produce burning at the edges
of adjacent commutator bars (see Fig. 24).
NOTE: For TungstenInertGas (TIG) Welded
Coil Leads: most large armatures have coils
which are TIG welded to the commutator risers,
instead of soldered. TIG welded coil connec
tions contain no solder; therefore, signs of over
heating for TIG welded coils are limited to
burned coilinsulation, heat discoloration of the
copper or melting of the coil leads.
An open circuit in an armature winding can also oc
cur from a conductor being broken due to poor handl
ing or vibration. Then, current cannot get through the
winding and an arc is drawn as the segments, to which
the broken coil is connected, move away from each
brush. This burns the copper away on adjacent edges
of consecutive bars and makes a deep trench as
shown in Fig. 25. At high speed and voltage a flashover
may occur.
COMMUTATOR INSULATION
The purpose of electrical insulation is to prevent
leakage of electric current. If leakage does occur, suffi
cient heat may result to carbonize the surface of the in
sulation and destroy its insulating value.
The commutator is insulated from ground by the
cone and shell insulation (Fig. 4) which must withstand
the full operating voltage of the machine. The cone in
sulation presents relatively long creepage surfaces at
each end of the commutator. On most transportation
machines, a Teflon creepage band is used to protect
the exposed creepage surface of the mica cone on the
end of the commutator opposite the risers. Both Teflon

13
MI31100017A
GEI85167A, COMMUTATOR MAINTENANCE
FIG. 25. OVERHEATING CAUSED SOLDER TO
MELT OUT OF THIS ARMATURE. THE OPEN
CIRCUIT IN ONE COIL CAUSED DEEP BURNING
OF ADJACENT COMMUTATOR BARS. E7843.
and string creepage bands should be wiped clean peri
odically to retain their full insulating value.
Each pair of commutator bars has the voltage of
one armature coil between them. If the mica plate,
which insulates the bars, is bridged by conducting ma
terial, the bars will be short circuited. Current flowing
across this conductive bridge will heat the material and
cause it to carbonize and glow. At high armature speed
this hot spot may trigger a flashover.
INSPECTION
Visual inspection of a commutator will detect the
majority of defects previously mentioned. To learn
more, you must feel, listen, or measure. If a traction mo
tor is out of the truck, if the wheels are jacked clear of
the rails, or if a droppit table is lowered, you can run the
motor and feel or hear a rough commutator. A genera
tor and its auxiliaries may be checked for a rough com
mutator while the engine is idling.
A distinct click can be heard as each brush goes
over a step in the commutator surface; or the brushes
will chatter as rough spots disturb them. Hold a fiber or
wooden stick, about the size of a long pencil, lightly on
the brush or on the spring right over it. This will give you
the feel of the brush as it rides the commutator. The bad
spots can be felt clearly as they go by. Check traction
motor commutators in both directions of rotation to see
if there is a difference in the degree of roughness.
14
The most accurate way to check a commutator sur
face is with a dial indicator (capable of reading 1/10 of
one mil). Attach it to the frame with a flattipped pointer
resting against the commutator. Slowly rotate the ar
mature by hand and measure commutator runout on
all brush paths. On most machines (on newly resur
faced commutators) maximum allowable runout in any
brush path is 0.001 in. TIR with a rate of change of
0.0004 in. within any group of 20 bars and 0.001 be
tween adjacent bars. Refer to the device instruction
book for commutatorrunout data for a specific ma
chine.
RESURFACING THE
COMMUTATOR
Commutator troubles may often be corrected by
resurfacing. This is the name given to any process
which restores a true, cylindrical, polished surface to
the commutator.
NOTE: Reference to procedures such as Air
Curing," Testing" and Resurfacing" should
not be attempted without also reading the ap
propriate instructions for such procedures, in
the instruction book for the machine being
maintained.
POLISHING
If the commutator surface is merely smudged, you
can clean it by polishing with canvas. When this is not
sufficient, or if the commutator is slightly rough, crocus
cloth, fine (4/0) sandpaper, or 400A Triemite* paper
may be used. This should be mounted on a wooden
block curved to fit the surface of the commutator as
shown in Fig. 26.
CAUTION: Never use emery cloth on a commu
tator. The abrasive particles not only scratch
the surface, but they are conductive and lodge
between commutator segments. This leads to
short circuits.
*Reg. trademark of Minnesota Mining & Mfg.
Co.
 MI31100017A
COMMUTATOR MAINTENANCE, GEI85167A

a grinding fixture mounted on the machine. A grinding

fixture has a movable carriage for traversing the stone
across the commutator surface and a feed to regulate
the cut of the stone. A vacuum attachment is also avail
able to pick up copper chips and abrasive dust. See
the Tool Catalog for grinding fixtures and graded cut
ting stones applicable to various machines.
FIG. 26. FINE GRAIN SANDPAPER ON A SHAPED Stoning with a grinding fixture is faster and requires
WOODEN BLOCK. E8778.
less skill than hand stoning. Also the fixture, because it
is rigidly mounted, will trueup a commutator that is out
ofround (Figs. 28 and 29).

TURNING
If a commutator is badly worn or burned, the resur
facing operation should be performed in a lathe. Set
the cutting speed of the lathe for 300 surface feet per
minute and use a carbide tipped cutting tool. The ar
mature should be supported on its own bearings if pos
sible. If not, mount the armature between centers but
be sure the centers are true with respect to the bearing
seats or the commutator will be outofround. Remove
only enough copper from the commutator to give a uni

FIG. 27. PROPER USE OF HAND STONING.

E8779A.

STONING

If the commutator surface is mildly grooved,

etched, or burned, and only a small amount of copper
has to be removed to correct the defect, a hand stone is
most suitable. The stone should have a surface curved
to fit the commutator. Also, it should be long enough to
bridge the defect to be removed; otherwise, the stone
will ride in and out of the defect and do nothing to cor
rect it. The length of the stone will usually be limited by
the space between brushholders. If there is not enough
space, a brushholder should be removed to make
room for a larger stone (Fig. 27).

Hand stoning will not correct an outofround com

mutator. It is a fairly difficult operation and should be
performed only by knowledgeable, skilled personnel.

When a greater amount of copper is to be removed, FIG. 28. COMMUTATOR GRINDING FIXTURE IN
or the defect is too large to be bridged by the stone, use POSITION ON MOTOR. E498.

15
MI31100017A
GEI85167A, COMMUTATOR MAINTENANCE
FIG. 29. COMMUTATOR GRINDER INSTALLED IN
GENERATOR. E485B.
form surface. Then, use a coarse stone followed by a
finish polish.
UNDERCUTTING
After a commutator has been resurfaced, check the
depth of the undercut of the mica between bars. If un
dercutting is necessary, it should be done carefully with
a proper tool of correct size. The tool must have a sharp
edge to cut the mica freely. A dull blade or saw pro
duces small cracks in the mica into which dirt or mois
ture may find its way and break down the insulation be
tween commutator bars.
Some common mistakes are shown in Fig. 30.
Avoid these mistakes, refer to the device instruction
book for the slot width and depth dimensions.
16
ÉÉ ÉÉÉ É ÉÉ
ÉÉÉÉ ÉÉÉ É ÉÉ
ÉÉÉÉ ÉÉÉ É ÉÉ
É É
ÉÉÉÉ ÉÉ
A. MICA PROPERLY UNDERCUT.
B. UNDERCUTTING TOOL TOO NARROW, LEAVING FIN
AT ONE SIDE OF SLOT.
C. UNDERCUTTING TOOL VERY NARROW, LEAVING
FINS AT BOTH SIDES OF SLOT.
D. SLOT IMPROPERLY INDEXED, PART OF BAR CUT
AWAY AND FIN OF MICA LEFT.
E. TOOL TOO WIDE, PART OF BAR CUT AWAY.
F. UNDERCUTTING TOO SHALLOW, SERVICE LIFE
SHORTENS BEFORE NEXT UNDERCUTTING.
G. UNDERCUTTING TOO DEEP, POCKET COLLECTS
CARBON AND COPPER DUST, SHORT CIRCUITING
BARS.
FIG. 30. COMMON MISTAKES IN UNDERCUTTING
THE MICA BETWEEN COMMUTATOR SEGMENTS.
E5024A.
A section of a hacksaw blade secured in a home
made holder cuts a satisfactory slot for small commuta
tors provided a sharp blade is used and kept parallel to
the sides of the slots. Do not let the blade lean or
wobble. Saw lightly until the mica is down to the re
quired depth (given under MAINTENANCE DATA in
individual instructions).
For an occasional undercutting job you may want to
use a hand slotter and scraper with a toolsteel bit.
Draw this tool lightly through the commutator slots. The
same tool also cleans slots, smooths burrs, and re
moves mica fins if you have undercut the commutator
with a powered undercutter.
We do not recommend the use of handheld motor
powered undercutting tools. Select a motor powered
tool that can be rigidly mounted on a lathe. One slip of a
hand held tool can damage bars or risers or the Teflon
creepage band and ruin a serviceable commutator  or
cause an injury. If you are in the market for a powered
undercutting tool, we suggest you select a tool that has
a slot guide and a depth gage. Follow the instructions
of the tool manufacturer and make a few practice un

(A) SLOT RAKING TOOL
(B) CLEANING OUT SLOTS IN INNER
BRUSH PATH.
FIG. 31. CLEANING COMMUTATOR SLOTS. E25145.
dercuts on a scrap commutator to get the feel" of the
tool. In general the width of the cutter should be about 2
times the width of the dust groove.
SLOT RAKING AND
BRUSHING
Resurfacing operations usually leave copper par
ticles and slivers on the edges of the commutator bars
and in the slots. These must be removed before the
machine is placed in service as they could cause a
flashover. Use a brush with stiff nylon bristles, a piece of
fiberboard or a special tool ground to fit the slot (Fig. 31
B,C) and clean the slots thoroughly. Use a slot raking
tool (Fig. 31A) and break the sharp edges of the bars.
MI31100017A
COMMUTATOR MAINTENANCE, GEI85167A
(C) CLEANING OUT SLOTS ON OUTER
BRUSH PATH.
If resurfacing has produced considerable copper
drag on the bar edges, a V"shaped slotraking tool
should be used to remove fins and ragged edges from
the bars. Insert the point of the tool in the slot so the
sides of the tool will scrape the edge of the bar on each
side of the slot as the tool is dragged along the slot.
After the slots have been cleaned it may be neces
sary to use very fine sandpaper or crocus cloth to re
move small burrs and slivers from the edges of the
bars. Don't use emery cloth.
AIR CURING THE COMMUTATOR
Air curing is a procedure which uses compressed
air centrifugal force and the machine voltage to remove
the copper particles remaining in the commutator slots
17
MI31100017A
GEI85167A, COMMUTATOR MAINTENANCE
after the slots have been hand cleaned. In the process,
armature speed is varied from low to maximum rpm;
therefore, before a motor commutator can be air cured,
arrangements must be made to separately excite the
field to prevent the motor from overspeeding at no load
and full voltage.
To air cure a generator mounted on a vehicle, the
power contactors are blocked open and the armature
speed is controlled by regulating the speed of the ve
hicle engine.
In the air curing procedure, the armature is rotated
at low speed and a strong jet of compressed air is
swept across the surface of the commutator. The air
stream and voltage dislodge and remove any copper
particles remaining in the slots. Small sparks seen dur
ing the curing process indicate the removal of copper
particles. When sparking stops, armature speed is in
2901 East Lake Road
Erie, Pennsylvania 16531
NEW 10-83, WLF
18
creased. The curing procedure is continued until no
sparking is evident at full armature speed.
SAFETY PRECAUTIONS
When working on commutators, always wear
goggles and gloves for protection against flying par
ticles or the possibility of a flashover when air curing. A
respirator should be worn during stoning and jig grind
ing operations to filter abrasive dust from the air.
Stoning a commutator with the brushes in place will
wear the brushes away very rapidly and cause carbon
dust to deposit on insulation. Brushes that are hardto
reach should be removed before the engine is started if
you are working on an enginedriven generator. After
cranking, additional brushes can be taken out. In the
case of motors, the good brushes should be removed,
and worn brushes substituted. Usually one brush in
each holder is enough to run the motor light.
GE Transportation
Systems
PRINTED
IN U.S.A.
E
 MDS-UB3 GEK-91658
GE752 HIGH TORQUE HORIZONTAL DRILLING MOTOR

MODEL DIFFERENCE SHEET

GE752 HIGH TORQUE
HORIZONTAL DRILLING MOTOR

SCOPE DESCRIPTION

The GE752UB3 is the same as the GE752RB3 except

the UB3 has a double-ended shaft.
This Model Difference Sheet is issued to update the
Refer to Table 1 in this MDS which is a listing of drawĆ
instructions in the basic publication, GEK-91658.
ing references. It has been ubdated by adding the
Upon its issuance, this Model Difference Sheet will beĆ
UB3.
come part of the basic publication. Therefore, both
documents should be kept together for easy reference. Refer to Fig. 1 for an outline drawing of the UB3.

ECopyright 1993 General Electric Company. All rights reserved. This copyrighted document may be reproduced free of charge by General
Electric Company customers (OEM's) and their customers, if such reproduction is used exclusively in connection with equipment used in those
customers' internal operations.

These instructions do not purport to cover all details or variations in equipment nor to provide for every possible contingency to be met in connection with installation, operation, or
maintenance. Should further information be desired or should particular problems arise which are not covered sufficiently for the user's purposes, the matter should be referred to the
General Electric Company. Any applicable Federal, State or local regulations or company safety or operating rules must take precedence over any instructions given in this material. GE
has no obligation to keep the material up to date after the original publication.
THERE ARE NO WARRANTIES OF ACCURACY, MERCHANTABILITY OR FITNESS FOR PARTICULAR PURPOSE.
Verify numbers for parts, tools, or material by using the Renewal Parts or Tool Catalogs, or contact your General Electric repreĆ
sentative for assistance.
Do not order from this publication.
GEK-91658 MDS-UB3
GE752 HIGH TORQUE HORIZONTAL DRILLING MOTOR

TABLE 1

GE752 GE752 GE752 GE752 GE752 GE752 GE752 GE752

ARB1 ARB2 ARB3 RB1 RB2 RB3 UB1 UB3
Instruction Book Fig. 25 Fig. 26 Fig. 25 Fig. 25 Fig. 26 Fig. 26 Fig. 27 Fig. 27
Longitudinal
Puller Tools Comm. Fig. 22 Fig. 22 Fig. 22 Fig. 22 Fig. 22 Fig. 22 Fig. 22 Fig. 22
End
Puller Tools Pinion Fig. 24 Fig. 24 Fig. 24 Fig. 24 Fig. 24 Fig. 24 Fig. 24 Fig. 24
End
Armature Fig. 29 Fig. 29 Fig. 29 Fig. 29 Fig. 29 Fig. 29 Fig. 30 Fig. 30
Shaft
Connection Fig. 37 Fig. 37 Fig. 37 Fig. 35 Fig. 36 Fig. 36 Fig. 35 Fig. 36
Diagram
Coiled Frame Fig. 39 Fig. 39 Fig. 39 Fig. 38 Fig. 38 Fig. 38 Fig. 38 Fig. 38
Assembly
Bearing Grease Dis- Fig. 42 Fig. 42 Fig. 42 Fig. 42 Fig. 42 Fig. 42 Fig. 42 Fig. 42
trib. Drive End
Bearing Grease Dis- Fig. 43 Fig. 43 Fig. 43 Fig. 43 Fig. 43 Fig. 43 Fig. 44 Fig. 44
trib. Comm. End
Armature Fig. 48 Fig. 48 Fig. 48 Fig. 48 Fig. 48 Fig. 48 Fig. 49 Fig. 49
Locking Arrangment
Connection Fig. 53 Fig. 54 Fig. 50 Fig. 52 Fig. 51 Fig. 50
Box
Outline Fig. 58 Fig. 60 Fig. 58 Fig. 55 Fig. 57 Fig. 55 Fig. 61 Fig. *

Outline Fig. 59 Fig. 56

*See Fig.1 in this MDS.

NOTES

2
MDS-UB3 GEK-91658
GE752 HIGH TORQUE HORIZONTAL DRILLING MOTOR

NOTES

3
GEK-91658 MDS-UB3
GE752 HIGH TORQUE HORIZONTAL DRILLING MOTOR

WEIGHT OF MOTOR 6721 LBS. [3048.6 kg]

WEIGHT OF (OPTIONAL) BLOWER ASM. 396 LBS. [179.6 kg]

NOTES:
1) DIMENSIONS: INCHES [MILLIMETERS] .50-13 TAP
1.00 [25.4] DEEP
2) NO CONSTANT THRUST LOAD OF 6 HOLES
ANY MAGNITUDE TO BE APPLIED
TO MACHINE BEARINGS.
1.13
NOTE FOR ARMATURE LOCKING ARRANGEMENT: [28.7]
LOCATED ON COMMUTATOR END,
C MOTOR
TO BE IN PLACE DURING MOUNTING
OF MOTOR, BUT TO BE REMOVED L
PRIOR TO MOTOR OPERATION.
13.50
IMPORTANT:
THE ELECTRICAL EQUIPMENT SHOULD [342.9]
BE LOCATED IN A SPACE WHICH
1) PROVIDES SUFFICIENT ACCESSIBILITY
FOR BRUSH INSPECTION.
2) ALLOWS FOR REMOVAL OF ALL BRUSHES
AND PIGTAIL FASTENERS.
3) ALLOWS MAINTENANCE PERSONNEL TO
COMPLY TO THE GE MAINTENANCE
INSTRUCTION SPECIAL REQUIREMENTS.

9.50
[241.3]

12.87
[326.9]

CONNECTION BOX ENCLOSURE

AIR INLET FLANGE
PER IP24, IEC 34-5
AS SHOWN MOUNTED.
SEE CONNECTION BOX
DETAILS ON SHEET #2.
AUXILIARY
SWITCH
AIR
OUT .50 NPT FOR
APPROX. CENTER OF AIR PRESSURE
GRAVITY LOCATED AT MEASUREMENTS
MOTOR CENTERLINES
WARN.
SHAFT TAPER PLATE
1.25 [31.75] IN DIA.
PER 12.00 [304.8] IN
LENGTH 11.360 +
- .005
[288.54 +
- 0.13]
DIA.

.50 NPT FOR

AIR PRESSURE A1
MEASUREMENTS C
L ARM WARN.
A2 PLATE
EXPLOSION PROOF
PRESSURE SWITCH
#6 SCREWS ON
TERMINAL BOARD

58.50
[1485.9]

GE-752-UB3A MOTOR

FIG. 1. GE752UB3 OUTLINE DRAWING (41E903835, CHG. 0). E-41174.

4
 MDS-UB3 GEK-91658
GE752 HIGH TORQUE HORIZONTAL DRILLING MOTOR

.625-11 TAP 2.25 DIA

1.25 [31.8] DP. [57.2 DIA.]
4 HOLES
3 HOLES
FOR LIFTING

AIR
OUT

EXPLOSION PROOF
PRESSURE SWITCH
#6 SCREWS ON
TERMINAL BOARD

.50-13 TAP THIS AREA OF FOOT

1.00 [25.4] DEEP TO BE FLUSH WITH
8 HOLES FRAME FACE, BOTH
SIDES
PINION END

END OF
SHAFT C
L MOTOR
REFERENCE

18.25 [463.6] 18.25 [463.6]

16.50 [419.1] 16.50 [419.1]

9.25 1.74 3.19
[235.0] [81.0]
[44.2]

5.25 8.25
2.38 [60.5]
[133.4] [209.6]

15.37 REF.
[390.4] 1.00 R
3.87 [98.3]
23.12 [25.4 R]

[587.2] 10.75
[273.0]
CL ARM.
2.50
[63.5]
1.00
[25.4]

4.25 6.50
[108.0] [165.1]
1.35
[34.3]

1.56 DIA. THRU .375-16 X 1.19

26.13 GROUNDING STUD 30
[39.6 ] AND
[663.7] 3.00 DIA. S'FACE. (ON TOP OF FOOT)
1.25 [31.8]
[76.2 ] ON TOP .75-10 THD. THRU
SIDE - 4 HOLES 4 HOLES FOR
JACKING AND
GROUND CABLE
END OF
SHAFT
REFERENCE
MOUNTING FEET

FIG. 1. GE752UB3 OUTLINE DRAWING (41E903835, CHG. 0), E-41174.

5
GEK-91658 MDS-UB3
GE752 HIGH TORQUE HORIZONTAL DRILLING MOTOR

A MINIMUM CLEARANCE
REQUIRED FOR
BRUSH ACCESSIBILITY
AUXILIARY
SWITCH
NAME 21.00
PLATE
[533.4]

TAPPED HOLES ARE PRESENT

IN STD. MOTOR FRAME BUT
NOT USED FOR THIS MODEL

10.25 12.50
[260.4] [317.5]
A2
A1

C 12.00
646 MCM APPROX. 1.25-7 TAP [304.8]
UNARMORED CENTER OF 1.75 [44.5] DEEP
CABLES GRAVITY 2 HOLES
B VIEW AT A
TOP INSPECTION FLANGE
COMMUTATOR END

TAPPED HOLES ARE PRESENT

TAPPED HOLES ARE PRESENT IN STD. MOTOR FRAME BUT
IN STD. MOTOR FRAME BUT NOT USED FOR THIS MODEL .50-13 TAP THRU
NOT USED FOR THIS MODEL .50-13 TAP THRU 4 HOLES
4 HOLES

8.00 11.00 13.25

10.25
203.2 [279.4] [336.6]
260.4

8.00 .81 FLAT

.81 FLAT 8.00 1.13
[203.2] [20.6] [20.6] [203.2] [28.7]

12.00 12.00
[304.8] [304.8]

VIEW AT B VIEW AT C
HAND HOLE FLANGE SPACE HEATER FLANGE

FIG. 1. GE752UB3 OUTLINE DRAWING (41E903835, CHG. 0), E-41174.

6
 MDS-UB3 GEK-91658
GE752 HIGH TORQUE HORIZONTAL DRILLING MOTOR

4.25
.49 [12.4] [108.0]
1.00-14 TAP
2.25 [57.1] DEEP
12 HOLES EQ. SP.

+.000
+.000 9.120 DIA.
8.993 DIA. -.002
-.002 7.00 DIA.B.C.
.120-.130 +0.00
+0.00 [177.8] 5.38 DIA. 231.65
228.42 [3.05-3.30] -0.05
-0.05 ADVANCE
[136.7]

MOTOR HUB ASSEMBLY

.375-24 THREAD

11.88 14.00
1.83 [46.4]
[301.8] [355.6]

9.50 9.50
[241.3] [241.3]

NOTE:
BLOWER ARRGT. DIMENSIONALLY
SAME WHEN MOUNTED ON A" SIDE
1.00-8 THREAD
8.25 8.25
[209.6] [209.6] .75 [19.0]

2.00 [50.8]

OPTIONAL
VIEW SHOWING
BLOWER
ARRGT.
HYDRAULIC PUMP-OFF FOR HUB

DRAIN
NAME
PLATE

APPROX.
CENTER OF
GRAVITY

A1

A2

QUICK-OPEN COVER ARRGT.

WHEN SPACE HEATER IS
NOT SUPPLIED
GE-752-UB3B MOTOR
SAME AS GE-752-UB3A MOTOR EXCEPT
CONN. BOX MOUNTED ON OPPOSITE SIDE.
SHOWN HERE WITH OPTIONAL BLOWER ARRGT.

FIG. 1. GE752UB3 OUTLINE DRAWING (41E903835, CHG. 0), E-41174.

7
GEK-91658 MDS-UB3
GE752 HIGH TORQUE HORIZONTAL DRILLING MOTOR

IMPORTANT: 5.63
THE ELECTRICAL EQUIPMENT SHOULD [143.0]
BE LOCATED IN A SPACE WHICH
.25 1.12
1) PROVIDES SUFFICIENT ACCESSIBILITY
.938 [23.82] DIA. [6.4] [28.4]
FOR BRUSH INSPECTION. 8 HOLES EQ. SP.
2) ALLOWS FOR REMOVAL OF ALL BRUSHES
AND PIGTAIL FASTENERS.
3) ALLOWS MAINTENANCE PERSONNEL TO
COMPLY TO THE GE MAINTENANCE
INSTRUCTION SPECIAL REQUIREMENTS.
9.25 DIA.B.C. 7.25 DIA.
5.38 DIA. .090 - .100
[235.0] [2.3 - 2.5] [184.2]
[136.7]
ADVANCE
11.00 DIA. +.000
6.998 DIA.
[279.4] -.002
+0.00
177.75
-0.05

GENERATOR HUB ASSEMBLY

12.00 7.31 39.26

[304.8] [185.7] [997.2]

OPTIONAL
BLOWER
ARRGT.

AIR IN

A1
A2

GE-752-UB3B MOTOR
SAME AS GE-752-UB3A MOTOR EXCEPT
CONN. BOX MOUNTED ON OPPOSITE SIDE.
SHOWN HERE WITH OPTIONAL BLOWER ARRGT.

FIG. 1. GE752UB3 OUTLINE DRAWING (41E903835, CHG. 0), E-41174.

8
 MDS-UB3 GEK-91658
GE752 HIGH TORQUE HORIZONTAL DRILLING MOTOR

NOTE:
TO OBTAIN DESIRED SHAFT ROTATION AS
VIEWED FROM COMMUTATOR END OF MOTOR,
CUSTOMERS POWER CABLES SHOULD BE
CONNECTED WITH POLARITY AS SHOWN BELOW.

CCW CW
F1 F2 A1 A2 F1 F2 A1 A2
+ - + - - + + -
1.25-7 THREADS
2.17 [55.1] DEEP
2 PLACES
CHAIN CASE
BOSS

FRAME HEAD
AIR BAFFLE A B

A B

19.76 DIA. AIR

AIR [501.9] OUT
15.50 DIA.
OUT
[393.7]

D C

AIR D C
OUT

AIR AIR OUTLET SPLASH GUARDS MAY

OUT BE INTERCHANGED FOR CHAIN
PULL IN OPPOSITE DIRECTION

PINION END
VIEW SHOWING SPLASH GUARDS, FRAME HEAD
BAFFLES AND CHAIN CASE BOSSES (WHEN USED)

A B C D E F G H J K L M N P R S T V W X

PRESSURE SWITCH F1 HEATER

RTD'S
WHEN
SUPPLIED
AUXILIARY BLOWER GROUND STUD
F2
SWITCH (OPTIONAL) (IN BOX)

SCHEMATIC
TERMINAL BOARD CONNECTIONS

FIG. 1. GE752UB3 OUTLINE DRAWING (41E903835, CHG. 0), E-41174.

9
GEK-91658 MDS-UB3
GE752 HIGH TORQUE HORIZONTAL DRILLING MOTOR

20 POINT TERMINAL
BOARD W/#10 STUDS

.687 [17.4] DIA.

4 SETS OF 2 HOLES
FOR POWER CABLES

.75 [19.0]
MIN. CREEPAGE

B" SIDE CONN'S

AT THIS END 1.19-1.38 I.D.
1.19-1.38 I.D. [30.2-35.0 I.D.]
[30.2-35.0 I.D.] FOUR BUSHINGS
ONE BUSHING
(FOR CONTROL)

MAIN CONNECTION BOX DETAIL

BOLT-ON CONNECTIONS
SINGLE & DOUBLE POWER CONNECTIONS SHOWN
(CONNECTION BOX CONFORMS TO IEC 34-5 OF IP24)

20 POINT CONNECTOR .75 [19.0]

MIN. CREEPAGE

1.16 [29.5] DIA. HOLE

1.94 [49.3] DEEP 4 PLACES

MALE HALF OF CONNECTOR

IS SUPPLIED & CAN BE
CRIMPED TO 535 OR 777
MCM CABLE USING
"SQUARE D COMPANY'S"
VERSA-CRIMP TOOL,
PART NUMBER #VC-86

"B" SIDE CONN'S

AT THIS END 1.19-1.38 I.D.
1.19-1.38 [30.2-35.0] I.D .
[30.2-35.0 I.D.]
ONE BUSHING. 4.00 [101.6] DIA.
FOUR BUSHINGS
HOLE IN BOX. MAKE CONNECTIONS
PER 41C660816 (CONTROL) AND
TERMINAL BOARD SCHEMATIC

OPTIONAL MAIN CONNECTION B OX DETAIL

PLUG-IN CONNECTIONS
(CONNECTION BOX CONFORMS TO IEC 34-5 OF IP24)

FIG. 1. GE752UB3 OUTLINE DRAWING (41E903835, CHG. 0), E-41174.

10
MDS-UB3 GEK-91658
GE752 HIGH TORQUE HORIZONTAL DRILLING MOTOR

NOTES

11
GEK-91658 MDS-UB3
GE752 HIGH TORQUE HORIZONTAL DRILLING MOTOR

GE Transportation
Systems
2901 East Lake Road
NEW 6-93, WLF Erie, Pennsylvania 16531
PRINTED
IN U.S.A.
E

12
 GEK-47175B
INSPECTION AND MAINTENANCE
SCHEDULE
ELECTRIC DRILLING EQUIPMENT

DESCRIPTION hours. It is a suggested schedule and may not apply

exactly to every service environment.
This publication covers the inspection and mainteĆ
nance schedule of GE electric motors, generators and The time intervals are calculated to provide maxiĆ
blowers for the drilling industry. mum equipment life. However, certain adjustments
may be necessary because of actual operating condiĆ
The following schedule is based on operating tions.
ITEM EQUIPMENT PROCEDURE INTERVAL
(HOURS)
1. Electric Rotating Equipment: Blow out with clean DRY compressed air. 500
Main Generators Inspect brushes, brush holders (check
Drilling Motors spring pressure), commutator and leads.
Blower Motors
2. Control Devices: Check condition. Replace or dress up as
Contacts And Contact Tips (Copper, required.
Copper Alloy, And Silver)
3. Alarm And Protective Circuits Check for proper operation.
4. Control Compartment Blow out all compartments, equipment, 1000
and panels with DRY compressed air.
5. Control Circuits Visually inspect main control compartment 1500
and control panel. Make an operational
check.
6. Mounting Bolts: Check tightness 3000
Main Generators
Drilling Motors
Blower Motors
Chain Cases
7. Electric Rotating Equipment: In addition to Item 1 Ċ Test insulation resisĆ 6000
Main Generators tance. Stone commutator if necessary.
Drilling Motors
8. Contactors And Relays Clean and repair all contacts, interlocks,
shunts, chutes, and insulation. Replace as
necessary.
9. CP Contactors Add several drops of GE-D50E5B oil to
the air cylinders.
10. Terminals Check all terminal connections for tightĆ
ness.
11. Assignment Switches Check for proper operation.

These instructions do not purport to cover all details or variations in equipment nor to provide for every possible contingency to be met in connection with installation, operation, or
maintenance. Should further information be desired or should particular problems arise which are not covered sufficiently for the user's purposes, the matter should be referred to the
General Electric Company. Any applicable Federal, State or local regulations or company safety or operating rules must take precedence over any instructions given in this material. GE
has no obligation to keep the material up to date after the original publication.
THERE ARE NO WARRANTIES OF ACCURACY, MERCHANTABILITY OR FITNESS FOR PARTICULAR PURPOSE.
Verify numbers for parts, tools, or material by using the Renewal Parts or Tool Catalogs, or contact your General Electric repreĆ
sentative for assistance.
Do not order from this publication.
GEK-47175B, INSPECTION AND MAINTENANCE SCHEDULE

12. Meters Check calibration.

ITEM EQUIPMENT PROCEDURE INTERVAL
(HOURS)
13. Blowers Remove and clean fan blades and housĆ 6000
ings.
14. Electric Rotating Equipment: Remove, disassemble, clean, inspect and Every
Main Generators recondition as necessary (including varnish Three
Drilling Motors treatment of armature and fields). Repack Years
Blower Motors main generator and drilling motor bearings or
with GE-D65A2C10 grease. Repack reĆ 18000
maining motor and generator bearings hours
(equipped with fittings) with GE-D6A2C5
grease.
15. Control Equipment Overhaul all apparatus and replace worn
parts. Make necessary adjustments.
16. Electric Cables Replace cables that show low insulation
resistace or will not stand 75% above rated
voltage.

GE Transportation
Systems

2901 East Lake Road

Erie, Pennsylvania 16531
NEW 3-81, REB PRINTED
REVISED 10-90, WLF IN U.S.A.
E

2
..
.     

FIG0 30 BRAZING BURNED BRUSHHOLDERS0

EĆ116860

FIG0 60 BRUSHHOLDER CARBONĆWAY GAGE0

EĆ11683A0

 !5( $ %4$<,0* 614&+ $0' $


 ,0 ',$/(6(4
(2$,4 %475++1.'(45 '$/$*(' %; ).$5+18(45 $5 )1.>
%4$55 %4$<,0* 41' 61 27''.( ,0 57)),&,(06 /(6$. 61
.195 ,* 
 +1417*+.; &.($0 6+( $))(&6(' $4($ %; 9,4(
%475+,0* $0' *4,0' 1)) $0; /(6$. ).19 4(57.6,0*
)41/ $ ).$5+18(4
4(5614( 6+( /(6$. 6+$6 +$5 %((0 4(/18('
 +(&- 6+( &$4%109$; )14 5,<( 9,6+ 6+( =1 > 1>
1 *$*( $)6(4 6+( %475++1.'(4 +$5 &11.(' 61
411/ 6(/2(4$674(

 22.; $ 57,6$%.( %4$<,0* ).7: 57&+ $5  2(&  (5,<( $5 4(37,4(' %; 6+( /(6+1' '(5&4,%(' ,0


 61 6+( $4($ 61 %( %7,.6 72 6+( )14(*1,0*

 05(46 $ &$4%10 %475+ ,061 6+( &$4%109$; 61 24(> '',6,10$. ,05647&6,105 &18(4,0* /$,06(0$0&( $0'
8(06 6+( %4$<,0* /$6(4,$. )41/ ).19,0* ,061 6+( 4(&10',6,10,0* 1) %475++1.'(4 $55(/%.,(5 $4( &18(4('
9$; ,0 6+( > /1614 /$,06(0$0&( ,05647&6,105

 )&*(')++"'&
-*+!%*

 *+ #! '

)"! !&&*-$,&" 


# 
   

"
 


 GEK-101183D
VACUUM PRESSURE IMPREGNATION
(VPI) PROCESS

INTRODUCTION ARMATURE IMPREGNATION

The following process must be performed on an arĆ PROCEDURE
mature assembly and coiled motor frame after all reĆ 1. Surfaces that will require varnish to be removed
pairs have been completed. after impregnation should be coated with black
varnish (IMI-271 or equivalent). GE-RTV 128
The VPI process must be performed in a vacuum imĆ
silicone sealant, or equivalent, must be used on
pregnating tank with a nitrogen/dry air atmosphere. Do
threads and dummy bolts must be inserted in
not attempt to VPI unless all proper materials and
tapped holes.
equipment are available. Maintain all VPI temperatures
within a tolerance of ± 5°C (± 9°F). 2. Bake the armature for a minimum of four hours
at 155 ± 5°C (311 ± 9°F) or three hours at 175
The IMI-707C polyester varnish used in the VPI proĆ ± 5°C (347 ± 9°F). The armature must be
cess is catalyzed and normally stable, but it can set up cooled below 60°C (140°F) but not below 45°C
quite rapidly if vigilant care is not taken to avoid overĆ (113°F) before placing it in the VPI tank.
heating. Overheating of the varnish can be avoided by
3. Place the armature in the VPI tank with the comĆ
assurance of the following: 1) the item to be impregĆ mutator-end up (Fig. 3). Seal tank.
nated is within the specified temperature limits, and 2)
the cooling water is circulating through the holding 4. Start the vacuum and hold it below 3000 miĆ
tank and the tank agitator is operating at the time the crons for ten minutes. Record the final vacuum.
hot varnish is returned to the holding tank. Varnish visĆ If the final pressure is above 3000 microns, do
not proceed with the next Step until adequate
cosity limits are shown in Fig. 1 as a function of temperĆ
vacuum is obtained.
ature. To lower the viscosity, GE-775 viscosity reducer
is added as required. To raise viscosity, virgin 5. Stop the vacuum and transfer the varnish from
IMI-707C varnish is added as required. the holding tank to the VPI tank until the level of
solid varnish is approximately 1/4 in. above the
Gel time of the varnish should be within the limits riser on the commutator. A layer of foam will
shown in Fig. 2, as measured with a Sunshine gel meĆ form on the surface of the varnish. It is undesirĆ
ter or equivalent. If gel time falls below the minimum, able to allow the foam to go over the outer edge
GE-776 inhibitor solution should be added at the rate of the commutator bars on the armature. If necĆ
of three pints per 100 gallons. Gel time may be inĆ essary, knock down the foam with a small
amount of nitrogen. If the vacuum is less than 20
creased by adding uncatalyzed IMI-707C varnish if
in. of mercury, this cycle is not acceptable.
normal make-up varnish is needed.
Transfer the varnish back into the holding tank
and repeat Steps 4 and 5. If the cycle is acceptĆ
Revisions are indicated by marginal bars.
able, continue with the next Step.

ECopyright 1992, 1993 General Electric Company. All rights reserved. This copyrighted document may be reproduced free of charge by GenĆ
eral Electric Company customers, if such reproduction is used exclusively in those customers' internal operation.

These instructions do not purport to cover all details or variations in equipment nor to provide for every possible contingency to be met in connection with installation, operation, or
maintenance. Should further information be desired or should particular problems arise which are not covered sufficiently for the user's purposes, the matter should be referred to the
General Electric Company. Any applicable Federal, State or local regulations or company safety or operating rules must take precedence over any instructions given in this material. GE
has no obligation to keep the material up to date after the original publication.
THERE ARE NO WARRANTIES OF ACCURACY, MERCHANTABILITY OR FITNESS FOR PARTICULAR PURPOSE.
Verify numbers for parts, tools, or material by using the Renewal Parts or Tool Catalogs, or contact your General Electric repreĆ
sentative for assistance.
Do not order from this publication.
GEK-101183D, VACUUM PRESSURE IMPREGNATION (VPI) PROCESS

CAUTION: Ensure that cooling water and agitaĆ
tion are on in holding tank. Otherwise, the varnish
will overheat.
6. Open the nitrogen line and pressurize the VPI
tank; DO NOT EXCEED the maximum presĆ
sure of 100 psig. Hold the pressure above 70
psig for a minimum of 25 minutes.
7. Release the pressure by starting to transfer varĆ
nish to the holding tank. Once pressure is less
than 70 psig, vent the pressure to atmosphere
and continue to transfer varnish to the holding
tank.
8. Open the tank and allow the armature to drain
for several minutes. (To accelerate drainage
and remove excess varnish from pockets, the
armature can be spun for one minute using a
spinner tool, 41D789110G1.) Remove the arĆ
mature from the tank.
9. Gel bake the armature at 155 ± 5°C (311 ± 9°F)
for a 1.5-2 hours. Baking must start within 30
minutes after removal from the VPI tank and rollĆ
ing should be at a rate of 1/3 to 3 rpm.
10. Remove the armature from the oven. Allow the
armature to cool below 60°C (140°F) but not beĆ
low 45°C (113°F); repeat Steps 3 through 8.
NOTE: Do not clean previously protected maĆ
chined surfaces, threads, and tapped holes beĆ
fore varnish treating the armature.
11. Roll bake the armature at 155 ± 5°C (311 ±
9°F) for a minimum of 4 hours. Baking must
start within 30 minutes after removal from VPI
tank and rolling should be at 1/3 to 3 rpm.

80

70

60
ZAHN CUP (SECONDS)

50
MAXIMUM
MINIMUM

40

30

20
20 21 22 23 24 25 26 27 28 29 30

TEMPERATURE (_ C)

FIG. 1. IMI-707C VARNISH VISCOSITY CHART. E-41143.

2
 VACUUM PRESSURE IMPREGNATION (VPI) PROCESS, GEK-101183D

54

48

UPPER CONTROL POINT

40

32
TIME, MINUTES

24

16
LOWER CONTROL POINT

0
C 110 111 112 113 114 115 116
F 230 233.6 237.2 240.8

BATH TEMPERATURE

FIG. 2. VARNISH GEL TIME. E-40569.

COILED MOTOR FRAME
IMPREGNATION PROCEDURE
1. Surfaces that will require varnish to be removed
after impregnation should be coated with black
varnish (IMI-271 or equivalent). GE-RTV 128
silicone sealant, or equivalent, must be used on
threads and dummy bolts must be inserted in
tapped holes.
2. Bake the coiled frame for a minimum of four
hours at 155 ± 5°C (311 ± 9°F) or three hours at
175 ± 5°C (347 ± 9°F). The coiled frame must
be cooled below 60°C (140°F) but not below
45°C (113°F) before placing it in the VPI tank.
3. Tie all cable ends that are long enough well
above the varnish level. Seal shorter cables with
silicone tape to prevent stiff cables. If there is
any question of contamination of a terminal,
seal the terminal with unsupported (non-glass
backed) silicone rubber tape, 41A239176P127.
Areas of contact between rubber bushings and
rubber cables should be coated with a thin layer
of Dow Corning #107 silicone grease (or equivĆ
alent). Cable insulation not protected in this

3
GEK-101183D, VACUUM PRESSURE IMPREGNATION (VPI) PROCESS

COMMUTATOR
END

ARMATURE

VACUUM
PRESSURE
TANK

FIG. 3. PLACING ARMATURE IN TANK. E-40570A.

manner is subject to cracking and potential
electrical failure.
CAUTION: Excessive amounts of silicone grease
left on cables or bushings will degrade the
IMI-707C varnish.
4. Place the coiled frame in the VPI tank with the
pinion-end down (Fig. 4). Seal tank.
5. Start the vacuum and hold it below 2500 miĆ
crons for ten minutes. Record the final vacuum.
If the final pressure is above 2500 microns, do
not proceed with the next Step until adequate
vacuum is obtained.
6. Stop the vacuum and transfer varnish from the
holding tank to the VPI tank until the level of solĆ
id varnish is above the highest connection

4
 VACUUM PRESSURE IMPREGNATION (VPI) PROCESS, GEK-101183D

TIE CABLES TO
KEEP ABOVE
VARNISH LEVEL

RUBBER HOSE
EXTENSION FOR
SHORT CABLES

SHORT CABLES
WRAPPED WITH
SILICONE RUBBER COILED
TAPE MOTOR
FRAME

VACUUM
PRESSURE
TANK

FIG. 4. PLACING MOTOR FRAME IN TANK. E-40571.

strap. A layer of foam will form on the surface of Steps 5 and 6. If the cycle is acceptable, continĆ
the varnish. It is undesirable to allow the foam to ue with the next Step.
go over the brush holder supports. If necessary,
knock down the foam with a small amount of niĆ
CAUTION: Ensure that cooling water and agitaĆ
trogen. If the vacuum is less than 20 in. of merĆ
tion are on in holding tank. Otherwise the varnish
cury, this cycle is not acceptable. Transfer varĆ will overheat.
nish back into the holding tank and repeat

5
GEK-101183D, VACUUM PRESSURE IMPREGNATION (VPI) PROCESS

7. Open the nitrogen line and pressurize the VPI
tank; DO NOT EXCEED the maximum presĆ
sure of 100 psig. Hold the pressure above 70
psig for a minimum of 25 minutes.
8. Release the pressure by starting to transfer varĆ
nish to the holding tank. Once the pressure is
less than 70 psig, vent the pressure to atmoĆ
sphere and continue to transfer varnish to the
holding tank.
9. Open the tank and allow the coiled frame to
drain for several minutes. Remove the coiled
frame from the tank.
10. Wipe drips prior to braking with a clean, lint-
free cloth. Bake the coiled frame (hang at a 45
degree angle, pinion-end down) for four hours
at 155 ± 5°C (311 ± 9°F).
11. Remove the coiled frame from the oven. Allow
the coiled frame to cool below 60°C (140°F) but
not below 45°C (113°F); repeat Steps 4
through 10, except final bake the frame for six
hours at 155 ± 5°C (311 ± 9°F).

GE Transportation
Systems

NEW 3-92, JTO, WLF 2901 East Lake Road

Erie, Pennsylvania 16531
REVISED 9-92, WLF PRINTED
REVISED 12-92, WLF IN U.S.A.
REVISED 5-93, WLF E
REVISED 5-12-93, JTO

6
 GEX-12149
H83837D
11 MAY 2004

INDEX

FOR

DRILLING EQUIPMENT

FOR

DRILLING MOTORS
MODEL GE752 ARB3B

FOR

EMERI INTERNATIONAL

CUSTOMERS ORDER NO.

2003/27a

GE REQUISITION NUMBER

420-54461

NOTE: ADDITIONAL INFORMATION, IF REQUIRED, IS AVAILABLE FROM:

ARGO INTERNATIONAL
302 WEST 38TH STREET
HOUSTON, TEXAS 77018

ELECTRONIC COMPONENTS: SOME OF THE ELECTRONIC COMPONENTS LISTED IN

THIS CATALOG MAY BE PROCESSED OR ASSEMBLED IN ONE OR MORE OF THE
FOLLOWING COUNTRIES:

REPUBLIC OF SINGAPORE
REPUBLIC OF KOREA
REPUBLIC OF CHINA (TAIWAN)
BELGIUM
MALAYSIA

*ADDED OR CHANGED SINCE LAST ISSUE

COMPILED
10-29-93
CHANGED
6-7-94
COMPILED H83837D
10-29-93 GEX-12149

RENEWAL-PARTS CATALOG NO.

How to use this parts catalog Tk-2277B

Auxiliary Switch Assembly , Part No. 41a230022G01 DWG41A230022

Connection Box Assembly, Part No. 41D735140G14 GEG-26242005B

Terminal Board, Model 17BC17C1 PB-77000-003A

Connection Box Pressurizing Equipment, P/N 41B535164G1 PB-40104A

Heater Assembly, Part No. 41D735142G4 PB-40106A-Mod

Hub, Motor, 9.120 IN. O.D., Part No. 493A471P1 (1 Required)

Motor, Shunt Wound, Model 5GE752AB3B PB-31101-038

(Single End Shaft Extension)

Pressure Switch Assembly, Part No. 41C637215G1 PB-40107-002

HUNT ENGINE INC RENEWAL PARTS LIST ISSUE DATE 05/06/2004

RPL
4995G02 CONNECTION BOX ASSEMBLY
041D-735140-G14 SPECIAL,SEE 83837
SERIES / RB3 / TRIPLE BOLT-ON

HUNT PART
REF NO. QTY COMPONENT NUMBER

1.00 1 CONNECTION BOX ASSEMBLY 4995G2

1.01 1 BOX ONLY - BARE 4996

1.02 1 FRONT COVER PLATE W/GSKT. 3366.02B

1.03 2 GLAND PL. - LH,RH - DRILLED 4996.04.01

GLAND PL. - LH,RH - BLANK 4996.04
1.04 12 CABLE GLAND - 1" NPT 32 A2F-100NPT-7

1.05 2 GASKET - GLAND PL. - LH/RH 4996.06

1.06 1 GLAND PL. - CENTER - DRILLED 4996.05.01

GLAND PL. - CENTER - BLANK 4996.05
1.07 2 CABLE GLAND - 3/4" NPT 25 A2F-075NPT-7

1.08 1 GASKET - GLAND PL. - CENTER 4996.07

1.09 26 BOLT 1/4-20 X 1 N026-P21016-B13

1.10 26 LOCKWASHER 1/4 N405-P041-B13

1.11 26 NUT 1/4-20 N203-P021-B13

2.00 2 SUPPORT-STEEL 3503RAWMAT

3.00 4 CONN. STRAP-COPPER 041D-732583-G01

4.00 4 BOLT 3/4-10 X 1 3/4 N022-P35028-B13

4.01 4 LOCKWASHER 3/4 N405-P048-B13

5.00 4 BOLT 5/8-11 X 2 N022-P33032-B13

5.01 8 WASHER 5/8 NARROW N402-P017-B13

5.02 4 LOCKNUT 5/8"-11 041A-232345-P013

F:\WKSHEETS\EVERYONE\RPL\RPL2826.WK4
HUNT ENGINE INC RENEWAL PARTS LIST ISSUE DATE 05/06/2004

RPL
4995G02 CONNECTION BOX ASSEMBLY
041D-735140-G14 SPECIAL,SEE 83837
SERIES / RB3 / TRIPLE BOLT-ON

HUNT PART
REF NO. QTY COMPONENT NUMBER

6.00 8 INSULATOR ASSY 041B-537912-G01

6.01 8 NUT 3/8-16 N203-P025-B13

6.02 8 BOLT 3/8-16 X 3/4 N022-P25012-B13

6.03 16 WASHER 3/8 REG N402-P043-B13

7.00 1 TERMINAL BOARD ASSY 041A-250095-G10

7.01 21 NUT #10-32 N210-P016-B13

7.02 23 WASHER #10 NARROW N402-P009-B13

7.03 23 LOCKWASHER #10 N405-P039-B13

7.04 3 SCREW #10-32 X 3/4 N044-P16012-B13

7.05 3 THREADED INSERT #10-32 2976AP04

STRAIN RELIEF 1.5" NPT WITH 1.187

8.00 4 TO 1.375 BUSHING 499A-918DB-P021

8.01 4 LOCKNUT 1.50" NPT (PLAIN) 499A-918BA-P006

9.00 18 BOLT 5/16-18 X 3/4 N022-P23012-B13

9.01 18 LOCKWASHER 5/16 N405-P042-B13

9.02 18 THREADED INSERT 5/16"-18 2976AP07

10.00 1 ROTATION JUMPERS -"A" MTR. ONLY 5025G1

10.01 1 JUMPER - CW ROTATION - 8 1/8"L 5025P1

F:\WKSHEETS\EVERYONE\RPL\RPL2826.WK4
HUNT ENGINE INC RENEWAL PARTS LIST ISSUE DATE 05/06/2004

RPL
4995G02 CONNECTION BOX ASSEMBLY
041D-735140-G14 SPECIAL,SEE 83837
SERIES / RB3 / TRIPLE BOLT-ON

HUNT PART
REF NO. QTY COMPONENT NUMBER

10.02 1 JUMPER - CCW ROTATION - 14 1/4"L 5025P2

11.00 1 ROTATION JUMPERS -"B" MTR. ONLY 5025G2

11.01 1 JUMPER - CW ROTATION - 21"L 5025P3

11.02 1 JUMPER - CCW ROTATION - 14 1/4"L 5025P2

F:\WKSHEETS\EVERYONE\RPL\RPL2826.WK4
 

'"$%% 

    

  
     
 



  
   
 
 

  

!"+$&   $ &$ !" +

 $&% $%$( % !"+$& !' & +  $"$!' $ ! $ +  $
&$ !" + '%&!$%  %' $"$!'&! % '% *'%(+  ! &! )& #'" & '%  && '%&!$%  &$  !"$&! 

  

  
    

(Representative Illustration)
FIG. 1

  
   
   

  # !"" 




  
  
 


    
         
  
     
  
      

 
     


   

  

  
    

GE Transportation Systems, Erie, Pennsylvania 16531

  
     
  

 PB-40106A-MOD
SUPERSEDES PB-40106

GE Renewal Parts
Use original equipment parts for reliability

PARTS BULLETIN

HEATER ASSEMBlY
PART NUMBER 41D735142G4

DECEMBER 26, 1996

GE Transportation Systems
2901 East Lake Road
Erie. Pennsylvania 16531
 PB-40106A-MOD
PB-40106A H E A T E R A S S E M B L Y , P A R T N O . 41D73514264

-_-_--
r CONNECTION

5,16.17.18.19

---
---
---

10, I
11,
12
2

Ref. 1
(Represent~~~~llustration)

2 D E C E M B E R 26, 1 9 9 6
PB-40106A HEATER ASSEMBLY, PART NO. 41D735142G4 PB-40106A-MOD

QUANT
REQ.
FIG. REF. COL.
NO. NO. PART NO. A DESCRIPTION

1 1 41D735142G4 1 HEATER ASSEMBLY

1 2 41A239883P1 1 CONDULET
1 3 499A918BAP4 2 *LOCKNUT, 1 IN CONDUIT
1 4 N402P43B13 1 * W A S H E R , 3/8 I N
1 5 N405P43B13 1 *LOCKWASHER. 3/8 IN
1 6 N213P25B13 1 *NUT. H E X J A M . 3/8 I N - 1 6
1 7 N22P29020B13 4 B O L T , H E X HD. l/2 I N - 1 3 . 1 l/4 I N L O N G
1 8 N405P45B13 4 . “ L O C K W A S H E R . l/2 I N
1 9 41C636807P2 1 SPACE HEATER
1 10 41B537646G2 2 COVER
1 11 41B537646P2 2 GASKET, FELT, 0.250 IN THK. 9.60 IN LONG
1 12 41B537646P3 2 GASKET, FELT, 0.250 IN THK. 11.63 IN LONG
1 13 41B535116G18 1 *CABLE ASSEMBLY, APPROX 112 IN LONG (MARKED W)
1 14 41B535116G19 1 *CABLE ASSEMBLY, APPROX 112 IN LONG (MARKED V)
1 15 8832917P16 2 *TERMINAL, SOLDERLESS
1 16 N44P16005B13 2 *SCREW, SL FIL HD, NO 10-32, 5/16 IN LONG
1 17 N405P39B13 2 *LOCKWASHER. NO 10
1 18 N210P16B13 2 * N U T , H E X , N O l0-32
1 19 41B562849P133 AR *TAPE
1 20 502A208P4 1 * R E D U C I N G B U S H I N G , 3/4 I N T O 1 I N
1 21 499A918ABP3 2 *CONNECTOR. 3/4 IN C O N D U I T
1 22 155B9914ABP192 1 *CONDUIT, FLEXIBLE, 1 IN, 24 IN LONG
1 23 499A918BAP3 1 * L O C K N U T , 3/4 I N C O N D U I T

* ADDED OR CHANGED SINCE LAST ISSUE.

3 DECEMBER 26, 1996

PB-40106A HEATER ASSEMBLY, PART NO. 41D735142G4 PB-40106A-MOD

ILLUSTRATIONS

FIG. NO. PAGE

1 40106 2

GE Transportation
Systems
2901 East Lake Road
Erie. Pennsylvania 16531 7
 File: Airiomi
Revision: “B”
Page 1 of 5

INSTALLATION, OPERATING AND MAINTENANCE INSTRUCTIONS

HUNT AIRDYNE BLOWER MOTOR ASSEMBLY

Introduction:

The purpose of this manual is to aid in the proper installation and operation of Hunt Airdyne
Blower Motor assemblies manufactured by Hunt Engine, Inc. These instructions are intended to
supplement good general practices and are not intended to cover detailed instruction procedures,
because of the many varieties of airdynes manufactured by Hunt Engine, Inc.

It is the responsibility of the purchaser to assure that the installation and maintenance of this
equipment are handled by qualified personnel experienced in such work and equipment. Field
service personnel are available from Hunt Engine, Inc. to supervise installation or to assure
proper operation at startup.

Storage:

If airdynes are stored for any length of time, they should be stored in a clean, dry location to
prevent rust and corrosion. Outdoor storage is not recommended. When outdoor storage is
necessary, they should be protected from the elements as best possible. Cover the airdyne inlet
and outlet, and keep motors dry and clean.

Extended Storage:

Airdynes are to be stored in their original containers or equivalent protection and should be kept
in a clean, dry, protected warehouse where exercised control over temperature, dust, dew point,
shock and vibration is reasonable maintained.

A) Temperature: Between 50 degrees F and 120 degrees F

B) Maximum relative humidity of 60%

C) Shock or vibration: 2 mils maximum to prevent bearings from

brinelling. Exceeding this limit will require
vibration dampening material under the units.

Manually rotate blower once a month. All motors with space heaters are to have the heaters
connected if storage conditions exceed 60% relative humidity and/or if temperatures are below 50
degrees F.

Motor windings should be meggered at the time the equipment is put in storage. At the time of
removal from storage, the resistance reading must not have dropped more than 50% from the
initial reading. Contact Hunt Engine, Inc., if motor resistance is less than 50% of the initial
reading.

It is recommended that upon airdyne installation, the vibration levels be checked to assure that
the levels do not exceed the levels set forth in this manual. (See Table 1)

Storage records complying with the above requirements should be maintained.

 File: Airiomi
Revision: “B”
Page 2 of 5
Installation – Drilling Motor Mounted:

Installation of the Hunt Airdyne blower motor assembly onto a DC drilling motor is relatively
straight forward. Lock out the power source to the DC drilling motor as well as the power source
for the AC blower motor. Clean the mounting surface areas of both the DC drilling motor and the
Hunt Airdyne. Using the gasket and fasteners supplied in the installation kit, install the Hunt
Airdyne on the DC drilling motor. The Hunt Airdyne should be oriented on the DC drilling motor
so that when viewing the DC drilling motor from the commutator end (end opposite the drive hub),
you will be viewing the Hunt Airdyne from the rainhood end. The bolts should be torqued to 35 ft.
lbs. (425 in. lbs.)

The AC blower motor should be wired to its power source by a qualified electrician in a manner
that meets all applicable electrical codes. IMPORTANT! The AC blower motor must be wired to
rotate in the proper direction. The proper direction is indicated by an “arrow" nameplate affixed to
the blower housing. If the name plate is missing, look at the airdyne from the blower motor end.
If the blower outlet is offset to the left, the motor should rotate counterclockwise. If it is offset to
the right, it should rotate clockwise.

Start and run the airdyne long enough to confirm that it is operating properly. See following
trouble shooting chart. If any problem cannot be remedied, contact Hunt Engine, Inc.

Installation – Remote Mounted:

Remote installations of Hunt airdyne blower motor assemblies require advance engineering to
assure that the DC drilling motor is supplied with a sufficient amount of cooling air. Sizing of the
airdyne is determined by calculating the total pressure drop through the system, including
ductwork and drilling motor accessories. Installation procedures for each remote system are
therefore unique and it would not be practical to attempt to cover all possibilities herein. In
general, the basic concept is the same as for drilling motor mounted units. After installing the
system in accordance with the engineered design, check the system to confirm that it is operating
properly. Consult the trouble shooting guide if there is a problem. If the problem cannot be
remedied, contact Hunt Engine, Inc.

Maintenance - Blower:

Periodic inspection of all the airdyne parts is the key to good maintenance and trouble-free fan
operation. Frequency of inspection must be determined by the user and is dependent upon the
severity of the application. Prepare a maintenance schedule and make sure it is strictly adhered
to.

Never service or adjust rotating equipment while it is in operation. Lock out the power source
before performing maintenance.

Regular fan maintenance should include the following:

1) Check the airdyne impeller for any buildup of foreign material or wear
from abrasion. Both can cause excessive vibration, which will lead to
damage of the impeller and other fan components. Replace the impeller
if excessive wear is noticed. Carefully clean the impeller of any foreign
material.

2) Consult the trouble shooting guide for excessive vibration or noise,

insufficient performance, or when the airdyne does not operate. (See
Table 2.)
 File: Airiomi
Revision: “B”
Page 3 of 5
Maintenance – Blower Motor:

The fundamental principle of electrical maintenance is keep the motor clean and dry. This
requires periodic inspection of the motor, the frequency of which depends upon the type of motor
and the service.

Periodic checks of voltage, frequency, and current of a motor while in operating are
recommended. Such checks assure the correctness of frequency and voltage applied to the
motor, and yield an indication of the airdyne load. Comparison of these data with previous data
will give an indication of the airdyne performance. Any serious deviations should be investigated
and corrected.

Vibration:

Excessive airdyne vibration can be caused by many things. All possible sources of the excessive
vibration must be checked out and corrective action taken immediately to correct the problem.
See the airdyne trouble-shooting chart (Table 2) for possible causes of excessive airdyne
vibration.

A vibration analyzer will be of great assistance in determining the amount of vibration. The
following values give an indication of the airdyne vibration condition. Vibration readings should
be taken on the motor or on the airdyne housing. Horizontal, vertical, and axial readings should
be taken.

Table 1

Vibration Displacement in Mils, “Double Amplitude”

Fan RPM Good Fair Slightly Rough Rough

3000 0.02/0.45 0.45/1.00 1.00/2.00 2.00/4.00

3600 0.20/0.40 0.40/0.85 0.85/1.75 1.75/3.25

Interpolate for airdyne speeds other than shown above. The airdyne should not be operated
unless the maximum vibration reading is in at least the “Fair” range.

TABLE 2

Airdyne Trouble-Shooting Chart

Problem Possible Causes

_ Accumulation of material on impeller

Excessive _ Worn or corroded impeller
Vibration _ Bent shaft
_ Impeller loose shaft
_ Impeller out of balance
_ Motor out of balance
_ Loose or worn bearings
_ Loose bearing bolt
_ Loose impeller mounting bolts
_ Weak or resonant foundation
 File: Airiomi
Revision: “B”
Page 4 of 5

_ Foundation not flat and level

_ Structures not crossbraced

Horsepower _ Air density higher than design

to high _ Impeller rotating in the wrong direction

_ Impeller rotating in the wrong direction

Airflow
to low _ Actual system is more restrictive (more resistance to flow) than expected
_ Leaks or obstructions in duct work
_ Filters are dirty and clogged
_ Inlet our outlet screens are clogged
_ Restricted fan inlet or outlet
_ No straight duct at fan outlet
_ Sharp elbows near fan inlet or outlet
_ Improperly designed turning vanes

Airflow _ Actual systems is less restrictive (less resistance to flow) than expected
too much _ Filters not in place

Airdyne does _ Blown fuses

not operate _ Electricity turned off or not wired properly
_ Wrong voltage
_ Overload protector has broken circuit

Excessive _ Accumulation of material on impeller

noise _ Worn or corroded impeller
_ Bent shaft
_ Impeller loose shaft
_ Impeller hitting housing
_ Impeller out of balance
_ Loose or worn bearing
_ Defective or bad bearings
_ Loose airdyne mounting bolt
_ System pulsation or surge
_ Noise from high velocity system
_ Duct work to small
_ Fan in stall condition (danger)
_ Rattle of components in high velocity air stream
_ Leaks in duct work
_ Vibrating duct work
_ Vibrating parts not insolated from structure

Spare Parts:

Spare parts are not normally required for first year of operation. If spare parts are desired, it is
suggested that a spare blower motor and impeller be ordered.
 File: Airiomi
Revision: “B”
Page 5 of 5

Replacement Parts:

See replacement parts list for your particular airdyne blower motor assembly, identified by a Hunt
spec number and/or serial number.

For additional information concerning this product, please contact:

Hunt Engine, Inc. Phone: 713-721-9400 (24 Hours)

14805 South Main Fax #1: 713-721-7346 (24 Hours)
Houston, Texas 77035 Fax #2: www.huntengine.com
HUNT ENGINE INC RENEWAL PARTS LIST ISSUE DATE 03/25/2004

RPL
4991G03 HUNT AIRDYNE BLOWER MOTOR ASM
MODEL 752-15CCW-30380
SPEC 4991G03

HUNT PART
REF NO. QTY COMPONENT NUMBER

1.00 1 ELECTRIC MOTOR 5019

2.00 1 SUPPORT ASM-MOTOR 4700B

3.00 1 WHEEL ASM - CCW 3380AP06

4.00 1 HOUSING ASM 4992C

5.00 1 INLET TUBE ASM 3590.03B

6.00 1 RAINHOOD ASSEMBLY 3111C

7.00 1 NAMEPLATE - ROTATION - CCW 2969A

8.00 1 NAMEPLATE - MODEL, S/N ETC 2709A

9.00 1 INSTALLATION KIT 4991K

9.03 1 GASKET - BLOWER OUTLET 1447A

F:\WKSHEETS\EVERYONE\RPL\RPL2826.WK4
 R

MANUFACTURER GENERAL ELECTRIC

MANUFACTURER'S ID NO. 5KS254CAB128
B.H.P 15
R.P.M. - SYNCHRONOUS 3000
R.P.M. - FULL LOAD 2950
PHASE - Hz. 3 - 50
VOLTS - FULL LOAD 380
AMPS. - FULL LOAD 21.3
FRAME SIZE 254T
AMBIENT - DEG. C AT 1.15 SF 40
AMBIENT - DEG. C AT 1.00 SF 55
ENCLOSURE TEFC X-P (CLASS I GRP. D)
INSULATION CLASS F
TEMPERATURE CODE T2D
NEMA DESIGN B
EFF. % - FULL LOAD 91.7
LOCKED ROTOR CODE
U.L. FILE NO. - MOTOR E47088, E37792
U.L. FILE NO. - CONN BOX E47088
C.S.A. FILE NO. LR922, LR12467

HUNT ENGINE, INC.

HARVEY, HOUSTON,

TITLE
MOTOR DATA SHEET
DRAWN JDS PROJ.ENGR S/O

APPD. CHKD DWG.

NO. 5019MDS
DATE Mar 22, 2004 APPD

SCALE NTS DATE

REVISION NO. 0
 UNCONTROLLED COPY
Quality Control Work Instruction (QCW)
See on-line master for current
revision
HUNT ENGINE INC. - HOUSTON OPERATIONS DEDICATED TO CUSTOMER SATISFACTION Use AMIPRO File Manager to determine latest revision
SUBJECT: DOCUMENT I.D. REVISION NO.
Production Testing - Hunt Airdyne Blower Motor Assemblies QCW 4-10-01E 0

PURPOSE:

To Establish procedure for Production Testing of Hunt Airdyne Blower Motor Assemblies.

SCOPE:

Applicable to Production Department.

PROCEDURE:

1. Prepare Test Report Form QCD129 for each unit, completing all pre-test entries.

2. As indicated on Form QCD 129, affix unit (with Aircure, if applicable) to either the customer's DC drilling rig
motor, our test DC motor, our balometer or our adjustable static pressure fixture.

3. Connect AC power leads from our test control/monitoring panel to the AC blower motor. Power up unit.
Confirm that frequency meter reads 60 Hz. (or 50) +/- 1.0 Hz. Confirm that blower wheel is turning in
proper direction.

4. Observe and record the data called for on Form QCD 129.

5. The Test Technician signs off on Form QCD 129 and secures approval from Engineering.

6. Upon approval, the Test Technician checks, signs and dates Form 3121A (minilla tag) and wires it to the
Airdyne.

7. The completed test reports are then given to the Production Coordinator for insertion into the applicable
production order.

DEFINITIONS:

FORMS:

QCD 129 - Test Report (superceeds TR-104)

I - Indicates revised area(s) from previous issue

Form No. QCD103 Revision 0 (1 Jul 96)
ORIGINATED/REVISED BY: APPROVED BY: ISSUE DATE: PAGE
Grady E. Anderson Grady E. Anderson 26 July 96 1
 UNCONTROLLED COPY
Quality Control Work Instruction (QCW)
See on-line master for current
revision
HUNT ENGINE INC. - HOUSTON OPERATIONS DEDICATED TO CUSTOMER SATISFACTION Use AMIPRO File Manager to determine latest revision
SUBJECT: DOCUMENT I.D. REVISION NO.
Production Testing - Hunt Airdyne Blower Motor Assemblies QCW 4-10-01E 0

REFERENCES:

This QCW replaced TP-104

REVISION SUMMARY:

None - Oringinal Issue

DISTRIBUTION (Uncontrolled Copies):

All Departmental Managers

Corporate Headquarters

I - Indicates revised area(s) from previous issue

Form No. QCD103 Revision 0 (1 Jul 96)
ORIGINATED/REVISED BY: APPROVED BY: ISSUE DATE: PAGE
Grady E. Anderson Grady E. Anderson 26 July 96 2
Hunt Engine, Inc. Form: QCD129
Sheet Page 1 of 3 Revision: 3
Hunt Unit S/N: 83837D-1 Date: 19 Feb 04

TEST REPORT QCD129

HUNT AIRDYNE BLOWER MOTOR ASSEMBLY

1. PRE-TEST ENTRIES

1.1 HUNT PRODUCTION ORDER NO.: ____83837D

1.2 CUSTOMER: _ GE TRANSPORTATION SYSTEMS _____

1.3 CUSTOMER P.O. NO.: ____420-54461 ________________

1.4 PROJECT NAME: URALMASH

1.5 AIRDYNE TEST PERFORMED ON:

__ HUNT TEST DRILLING MOTOR

________ BALOMETER

________ ADJUSTABLE STATIC PRESSURE FIXTURE

__XXX__ CUSTOMER SUPPLIED DRILLING MOTOR

MANUFACTURER: GE

MODEL: ARB3B

SERIAL NO.: EE 0401 0012B

1.6 HUNT PRODUCT DATA

DESCRIPTION MODEL SPEC SERIAL NO.

1.6.1 AIRDYNE 752-15CCW-30380 4991G03 83837D-1

Hunt Engine, Inc. Form: QCD129
Sheet Page 2 of 3 Revision: 3
Hunt Unit S/N: 83837D-1 Date: 19 Feb 04

1.6 HUNT PRODUCT DATA (CONTINUED)

DESCRIPTION MODEL SPEC SERIAL NO.

1.6.2 AIRCURE, IF 752V LHB 2092 83837D-5

APPLICABLE

1.6.3 BLOWER WHEEL ROTATION

FACING MOTOR FAN C.W._ C.C.W._XXX

1.7 AC BLOWER MOTOR NAMEPLATE DATA

HUNT P/N : 5019 VOLTS : 380

BRAND : GE F.L. AMPS : 21.3

CATALOG : 5KS254CAB128 AMB.DEG C : 55º

SERIAL : OWP4065MM02E FRAME : 254T

HP : 15 ENCLOSURE: TEFC

RPM : 2950 S.F. : 1.0

PHASE : 3 U.L. CERT. :

HERTZ : 50 U.L. SEQ. : BT607076

2. AIRDYNE RUN TEST RESULTS

2.1 STATIC PRESS. WATER GAUGE 11.0 8.3” min.

2.2 BLOWER MOTOR R.P.M. 2981 -25 rpm

2.3 AMPS - A 13.1

2.4 AMPS - B 13.1

2.5 AMPS - C 13.1

Hunt Engine, Inc. Form: QCD129
Sheet Page 3 of 3 Revision: 3
Hunt Unit S/N: 83837D-1 Date: 19 Feb 04

2. AIRDYNE RUN TEST RESULTS (CONTINUED)

2.6 VOLTS - A 386

2.7 VOLTS - B 386

2.8 VOLTS - C 386

2.9 VIBRATION .8 0-1.0 mils

2.10 BAROMETRIC PRESSURE 30.0

2.11 INLET AIR TEMP. AT RAINHOOD 68

2.12 OUTLET AIR TEMP. 70

3. CERTIFICATION

HUNT ENGINE, INC. CERTIFIES THAT THE EQUIPMENT DESCRIBED

HEREIN WAS TESTED IN ACCORDANCE WITH TEST PROCEDURE
QCW 4-10-01E, LATEST REVISION, AND THAT THE DATA
RECORDED HEREIN ACCURATELY REFLECTS THE TEST RESULTS
AND RESULTS COMPARED TO APPLICABLE BLOWER CURVE.

GEORGE GRANADOS BRITT KELLER

HUNT TECHNICIAN HUNT TEST ENGINEER

3-16-04 3-22-04
DATE DATE

_____________________________
CUSTOMER REPRESENTATIVE

_____________________________
DATE
Hunt Engine, Inc. Form: QCD129
Sheet Page 1 of 3 Revision: 3
Hunt Unit S/N: 83837D-2 Date: 19 Feb 04

TEST REPORT QCD129

HUNT AIRDYNE BLOWER MOTOR ASSEMBLY

1. PRE-TEST ENTRIES

1.1 HUNT PRODUCTION ORDER NO.: ____83837D

1.2 CUSTOMER: _ GE TRANSPORTATION SYSTEMS _____

1.3 CUSTOMER P.O. NO.: ____420-54461 ________________

1.4 PROJECT NAME: URALMASH

1.5 AIRDYNE TEST PERFORMED ON:

__ HUNT TEST DRILLING MOTOR

________ BALOMETER

________ ADJUSTABLE STATIC PRESSURE FIXTURE

__XXX__ CUSTOMER SUPPLIED DRILLING MOTOR

MANUFACTURER: GE

MODEL: ARB3B

SERIAL NO.: EE 0401 0003D

1.6 HUNT PRODUCT DATA

DESCRIPTION MODEL SPEC SERIAL NO.

1.6.1 AIRDYNE 752-15CCW-30380 4991G03 83837D-2

Hunt Engine, Inc. Form: QCD129
Sheet Page 2 of 3 Revision: 3
Hunt Unit S/N: 83837D-2 Date: 19 Feb 04

1.6 HUNT PRODUCT DATA (CONTINUED)

DESCRIPTION MODEL SPEC SERIAL NO.

1.6.2 AIRCURE, IF 752V LHB 2092 83837D-6

APPLICABLE

1.6.3 BLOWER WHEEL ROTATION

FACING MOTOR FAN C.W._ C.C.W._XXX

1.7 AC BLOWER MOTOR NAMEPLATE DATA

HUNT P/N : 5019 VOLTS : 380

BRAND : GE F.L. AMPS : 21.3

CATALOG : 5KS254CAB128 AMB.DEG C : 55º

SERIAL : OWP4065MM01B FRAME : 254T

HP : 15 ENCLOSURE: TEFC

RPM : 2950 S.F. : 1.0

PHASE : 3 U.L. CERT. :

HERTZ : 50 U.L. SEQ. : BT607057

2. AIRDYNE RUN TEST RESULTS

2.1 STATIC PRESS. WATER GAUGE 11.0 8.3” min.

2.2 BLOWER MOTOR R.P.M. 2983 -25 rpm

2.3 AMPS - A 12.9

2.4 AMPS - B 12.9

2.5 AMPS - C 12.9

Hunt Engine, Inc. Form: QCD129
Sheet Page 3 of 3 Revision: 3
Hunt Unit S/N: 83837D-2 Date: 19 Feb 04

2. AIRDYNE RUN TEST RESULTS (CONTINUED)

2.6 VOLTS - A 386

2.7 VOLTS - B 386

2.8 VOLTS - C 386

2.9 VIBRATION .5 0-1.0 mils

2.10 BAROMETRIC PRESSURE 30.0

2.11 INLET AIR TEMP. AT RAINHOOD 68

2.12 OUTLET AIR TEMP. 69

3. CERTIFICATION

HUNT ENGINE, INC. CERTIFIES THAT THE EQUIPMENT DESCRIBED

HEREIN WAS TESTED IN ACCORDANCE WITH TEST PROCEDURE
QCW 4-10-01E, LATEST REVISION, AND THAT THE DATA
RECORDED HEREIN ACCURATELY REFLECTS THE TEST RESULTS
AND RESULTS COMPARED TO APPLICABLE BLOWER CURVE.

GEORGE GRANADOS BRITT KELLER

HUNT TECHNICIAN HUNT TEST ENGINEER

3-16-04 3-22-04
DATE DATE

_____________________________
CUSTOMER REPRESENTATIVE

_____________________________
DATE
Hunt Engine, Inc. Form: QCD129
Sheet Page 1 of 3 Revision: 3
Hunt Unit S/N: 83837D-3 Date: 19 Feb 04

TEST REPORT QCD129

HUNT AIRDYNE BLOWER MOTOR ASSEMBLY

1. PRE-TEST ENTRIES

1.1 HUNT PRODUCTION ORDER NO.: ____83837D

1.2 CUSTOMER: _ GE TRANSPORTATION SYSTEMS _____

1.3 CUSTOMER P.O. NO.: ____420-54461 ________________

1.4 PROJECT NAME: URALMASH

1.5 AIRDYNE TEST PERFORMED ON:

__ HUNT TEST DRILLING MOTOR

________ BALOMETER

________ ADJUSTABLE STATIC PRESSURE FIXTURE

__XXX__ CUSTOMER SUPPLIED DRILLING MOTOR

MANUFACTURER: GE

MODEL: ARB3B

SERIAL NO.: EE 0402 0029

CUSTOMER ID# 4469 100 TT
1.6 HUNT PRODUCT DATA

DESCRIPTION MODEL SPEC SERIAL NO.

1.6.1 AIRDYNE 752-15CCW-30380 4991G03 83837D-3

Hunt Engine, Inc. Form: QCD129
Sheet Page 2 of 3 Revision: 3
Hunt Unit S/N: 83837D-3 Date: 19 Feb 04

1.6 HUNT PRODUCT DATA (CONTINUED)

DESCRIPTION MODEL SPEC SERIAL NO.

1.6.2 AIRCURE, IF 752V LHB 2092 83837D-7

APPLICABLE

1.6.3 BLOWER WHEEL ROTATION

FACING MOTOR FAN C.W._ C.C.W._XXX

1.7 AC BLOWER MOTOR NAMEPLATE DATA

HUNT P/N : 5019 VOLTS : 380

BRAND : GE F.L. AMPS : 21.3

CATALOG : 5KS254CAB128 AMB.DEG C : 55º

SERIAL : PWP4122MM01H FRAME : 254T

HP : 15 ENCLOSURE: TEFC

RPM : 2950 S.F. : 1.0

PHASE : 3 U.L. CERT. :

HERTZ : 50 U.L. SEQ. : BT607111

2. AIRDYNE RUN TEST RESULTS

2.1 STATIC PRESS. WATER GAUGE 10.4 8.3” min.

2.2 BLOWER MOTOR R.P.M. 2952 -25 rpm

2.3 AMPS - A 12.6

2.4 AMPS - B 12.6

2.5 AMPS - C 12.6

Hunt Engine, Inc. Form: QCD129
Sheet Page 3 of 3 Revision: 3
Hunt Unit S/N: 83837D-3 Date: 19 Feb 04

2. AIRDYNE RUN TEST RESULTS (CONTINUED)

2.6 VOLTS - A 386

2.7 VOLTS - B 386

2.8 VOLTS - C 386

2.9 VIBRATION .4 0-1.0 mils

2.10 BAROMETRIC PRESSURE 30.1

2.11 INLET AIR TEMP. AT RAINHOOD 55

2.12 OUTLET AIR TEMP. 57

3. CERTIFICATION

HUNT ENGINE, INC. CERTIFIES THAT THE EQUIPMENT DESCRIBED

HEREIN WAS TESTED IN ACCORDANCE WITH TEST PROCEDURE
QCW 4-10-01E, LATEST REVISION, AND THAT THE DATA
RECORDED HEREIN ACCURATELY REFLECTS THE TEST RESULTS
AND RESULTS COMPARED TO APPLICABLE BLOWER CURVE.

GEORGE GRANADOS BRITT KELLER

HUNT TECHNICIAN HUNT TEST ENGINEER

4-12-04 4-22-04
DATE DATE

_____________________________
CUSTOMER REPRESENTATIVE

_____________________________
DATE
Hunt Engine, Inc. Form: QCD129
Sheet Page 1 of 3 Revision: 3
Hunt Unit S/N: 83837D-4 Date: 19 Feb 04

TEST REPORT QCD129

HUNT AIRDYNE BLOWER MOTOR ASSEMBLY

1. PRE-TEST ENTRIES

1.1 HUNT PRODUCTION ORDER NO.: ____83837D

1.2 CUSTOMER: _ GE TRANSPORTATION SYSTEMS _____

1.3 CUSTOMER P.O. NO.: ____420-54461 ________________

1.4 PROJECT NAME: URALMASH

1.5 AIRDYNE TEST PERFORMED ON:

__ HUNT TEST DRILLING MOTOR

________ BALOMETER

________ ADJUSTABLE STATIC PRESSURE FIXTURE

__XXX__ CUSTOMER SUPPLIED DRILLING MOTOR

MANUFACTURER: GE

MODEL: ARB3B

SERIAL NO.: EE 0402 0025

CUSTOMER ID# 4469 100 TT
1.6 HUNT PRODUCT DATA

DESCRIPTION MODEL SPEC SERIAL NO.

1.6.1 AIRDYNE 752-15CCW-30380 4991G03 83837D-4

Hunt Engine, Inc. Form: QCD129
Sheet Page 2 of 3 Revision: 3
Hunt Unit S/N: 83837D-4 Date: 19 Feb 04

1.6 HUNT PRODUCT DATA (CONTINUED)

DESCRIPTION MODEL SPEC SERIAL NO.

1.6.2 AIRCURE, IF 752V LHB 2092 83837D-8

APPLICABLE

1.6.3 BLOWER WHEEL ROTATION

FACING MOTOR FAN C.W._ C.C.W._XXX

1.7 AC BLOWER MOTOR NAMEPLATE DATA

HUNT P/N : 5019 VOLTS : 380

BRAND : GE F.L. AMPS : 21.3

CATALOG : 5KS254CAB128 AMB.DEG C : 55º

SERIAL : PWP4122MM01A FRAME : 254T

HP : 15 ENCLOSURE: TEFC

RPM : 2950 S.F. : 1.0

PHASE : 3 U.L. CERT. :

HERTZ : 50 U.L. SEQ. : BT607104

2. AIRDYNE RUN TEST RESULTS

2.1 STATIC PRESS. WATER GAUGE 10.5 8.3” min.

2.2 BLOWER MOTOR R.P.M. 2960 -25 rpm

2.3 AMPS - A 12.9

2.4 AMPS - B 12.9

2.5 AMPS - C 12.9

Hunt Engine, Inc. Form: QCD129
Sheet Page 3 of 3 Revision: 3
Hunt Unit S/N: 83837D-4 Date: 19 Feb 04

2. AIRDYNE RUN TEST RESULTS (CONTINUED)

2.6 VOLTS - A 386

2.7 VOLTS - B 386

2.8 VOLTS - C 386

2.9 VIBRATION .5 0-1.0 mils

2.10 BAROMETRIC PRESSURE 30.1

2.11 INLET AIR TEMP. AT RAINHOOD 57

2.12 OUTLET AIR TEMP. 61

3. CERTIFICATION

HUNT ENGINE, INC. CERTIFIES THAT THE EQUIPMENT DESCRIBED

HEREIN WAS TESTED IN ACCORDANCE WITH TEST PROCEDURE
QCW 4-10-01E, LATEST REVISION, AND THAT THE DATA
RECORDED HEREIN ACCURATELY REFLECTS THE TEST RESULTS
AND RESULTS COMPARED TO APPLICABLE BLOWER CURVE.

GEORGE GRANADOS BRITT KELLER

HUNT TECHNICIAN HUNT TEST ENGINEER

4-12-04 4-22-04
DATE DATE

_____________________________
CUSTOMER REPRESENTATIVE

_____________________________
DATE
 Hunt Engine, Inc.
14805 South Main
Houston, Texas 77035
Tel: 713-721-9400
Fax #1: 713-721-7346
Fax #2: 713-721-0343
www.huntengine.com

14 Feb 2003

WARRANTY POLICY

HUNT ENGINE, INC. MANUFACTURED PRODUCTS

Hunt Engine, Inc. warrants the equipment to be free from defects in material and workmanship that may develop
under normal use and service within one year following delivery of the equipment. Hunt Engine agrees to
correct such defects, which examination shall disclose to Hunt Engine’s satisfaction to be defective, by
repair or replacement F.O.B. Houston, Texas and such correction shall constitute fulfillment of obligation
with respect to such defect under this warranty.

This warranty shall be Hunt Engine’s sole obligation hereunder and is in lieu of all other warranties, express or
implied, including warranties of merchantability and fitness for a particular purpose, and all other obligation or
liabilities, including consequential damages or contingent liabilities arising out of failure of any part or item or
remanufacture to operate properly, and no person is authorized to give any other warranty or to assume any
additional obligation on Hunt Engine’s behalf unless made in writing and signed by an officer of Hunt Engine, Inc.

WARRANTY EXCLUSIONS

No warranty made by Hunt Engine, Inc. under this warranty policy shall be applicable unless Hunt Engine is given
prompt notice of the defect as soon as discovered.

Likewise, no warranty made by Hunt Engine, Inc. under this warranty policy shall extend to defects which result or
arise from (I) Willful or negligent operation or handling of the equipment or component parts by the customer or
user, (II) Alteration, modification or repair of the equipment or component parts by or at the direction of the
customer or user unless authorized in writing by Hunt Engine or (III) Adoption of such equipment to uses not
recommended by Hunt Engine, Inc.

INTELLIGENT CREATIVE SOLUTIONS – DRILLING MOTOR ACCESSORIES

 Hunt Engine Inc.
14805 South Main
Houston, Texas 77035
Tel: 713-721-9400
Fax #1: 713-721-7346
Fax #2: 713-721-0343

9 MAY 96 FILE: AIRCIOMI

REVISION:
PAGE 1 OF 2

HUNT AIRCURE AIR CLEANER

DC MOTOR/GENERATOR MOUNTED

INSTALLATION, OPERATING AND MAINTENANCE INSTRUCTIONS

INSTALLATION

INSTALLATION OF THE HUNT AIRCURE AIR CLEANER ON A DC DRILL RIG MOTOR OR

GENERATOR IS RELATIVELY SIMPLE. FIRST, AFTER DISCONNECTING THE POWER
FROM THE BLOWER MOTOR, REMOVE THE BLOWER MOTOR ASSEMBLY FROM THE
DC MOTOR/GENERATOR. NOW INSTALL THE AIRCURE ON THE COOLING AIR ENTRY
FLANGE, USING THE GASKET AND BOLTS PROVIDED IN THE INSTALLATION KIT.
INSTALL THE BLOWER MOTOR ASSEMBLY ON THE COOLING AIR ENTRY FLANGE OF
THE AIRCURE, USING THE OTHER GASKET PROVIDED IN THE INSTALLATION KIT
AND THE BOLTS WHICH ORIGINALLY WERE REMOVED WITH THE BLOWER MOTOR
ASSEMBLY. RECONNECT POWER TO THE BLOWER MOTOR, MAKING SURE THE
ROTATION OF THE BLOWER MOTOR IS CORRECT. THE BLOWER MOTOR ASSEMBLY
SHOULD BE EQUIPPED WITH A RAIN HOOD WHICH IN TURN SHOULD BE EQUIPPED
WITH AN INLET SCREEN TO PREVENT INGESTION OF TRASH, RAGS, INC.

OPERATION

THE HUNT AIRCURE AIR CLEANER IS AN INERTIAL SEPARATOR TYPE DEVICE. THE
BLOWER MOTOR ASSEMBLY DIRECTS COOLING AIR AT HIGH VELOCITY INTO THE
AIR ENTRY OPENING OF THE MOTOKLEEN. APPROXIMATELY TEN (10) PERCENT OF
THE COOLING AIR ALONG WITH 93.5% OF THE DIRT, MUD DUST, ETC. (5 MICRONS
AND LARGER) IS FORCED BY THE HIGH VELOCITY AIR STREAM INTO THE DUST BIN
AND THEN BACK OUT TO THE ATMOSPHERE. THE BALANCE OF THE COOLING AIR
(93.5% CLEAN) IS DIRECTED TO THE DC MOTOR/GENERATOR AFTER BEING FORCED
TO CHANGE ITS LINEAR DIRECTION TWICE.

INTELLIGENT CREATIVE SOLUTIONS - DRILLING MOTOR

9 MAY 96 FILE: AIRCIOMI
REVISION:
PAGE 2 OF 2

MAINTENANCE

THE HUNT AIRCURE AIR CLEANER IS VIRTUALLY MAINTENANCE FREE. IT

CONTAINS NO REPLACEABLE AIR CLEANER ELEMENTS OR MOVING PARTS. ON
THOSE INSTALLATIONS WHERE THERE IS OIL MIST OR DIESEL EXHAUST BEING
INTRODUCED INTO THE COOLING AIR STREAM, THERE IS THE POSSIBILITY OF A
DIRT/OIL BUILD-UP ON THE SEPARATOR BLADES. AN INSPECTION OF THE BLADES
ONCE A YEAR IS SUFFICIENT. IF IT IS DETERMINED THAT THE BUILD-UP IS
EXCESSIVE, REMOVE THE AIRCURE FROM THE DC MOTOR/GENERATOR AND CLEAN
THE UNIT USING A MEDIUM PRESSURE WATER BLAST, STEAM CLEANER OR
SOLVENT BATH. (*SEE NOTE.) BE SURE THE AIRCURE IS ABSOLUTELY DRY PRIOR
TO REINSTALLATION ON THE DC MOTOR GENERATOR.

*NOTE! WE HAVE A POPULAR MODEL WHICH FEATURES A REMOVABLE CELL

ASSEMBLY WHICH ALLOWS THE SEPARATOR BLADES TO BE CLEANED
WITHOUT HAVING TO REMOVE THE BLOWER MOTOR ASSEMBLY AND
AIRCURE FROM THE DC MOTOR/GENERATOR. YOU SIMPLY UNBOLT
THE REMOVABLE CELL ASSEMBLY, CLEAN IT AND REINSTALL IT. YOU
HAVE THIS DESIGN IF THE MODEL NUMBER CONTAINS THE SUFFIX
"-RC".

FOR INFORMATION CONCERNING THIS PRODUCT, PLEASE CONTACT:

HUNT ENGINE, INC.

14805 SOUTH MAIN
HOUSTON, TEXAS 77035

PHONE: 713-721-9400 (24 HOURS)

FAX #1: 713-721-7346 (24 HOURS)
FAX #2: 713-721-0343 (24 HOURS)
 8 7 6 5 4 3 1
2
THE INFORMATION CONTAINED IN THIS DRAWING IS THE SOLE PROPERTY OF REVISIONS
REV. DESCRIPTION DATE APPROVED
HUNT ENGINE, INC. ANY REPRODUCTION IN PART OR WHOLE WITHOUT

THE WRITTEN PERMISSION OF HUNT ENGINE, INC. IS PROHIBITED.

D D

3 6

C C

7 2

B B

4 1
5

ITEM PART OR NOMENCLATURE MATERIAL QTY

NO. IDENTIFYING NO. OR DESCRIPTION SPECIFICATION REQD

PARTS LIST

UNLESS OTHERWISE SPECIFIED CAD GENERATED DRAWING,

HUNT ENGINE, INC.

DIMENSIONS ARE IN INCHES
DO NOT MANUALLY UPDATE
TOLERANCES ARE:

FRACTION S DECIMALS ANGLES A

A .06 .XX .03 .5 APPROVALS DATE
DRAWN
.XXX .005 RWP 1/18/00
SHOP ASSEMBLY
MATERIAL
CHECKED
SPEED SENSOR APPLICATION
VARIOUS RESP ENG DIGITAL ENCODER
FINISH
MFG ENG
SIZE DWG. NO.
NEXT ASSY USED ON
-- REV.

QUAL ENG B 4539B 0

APPLICATION DO NOT SCALE DRAWING SCALE 1/2 CAD FILE: 4539B SHEET 1 OF 1
8 7 6 5 4 3 2 1
DATE PRINTED 05/06/2004 RENEWAL PARTS LIST PAGE 1

RPL 4539G2
SPEED SENSOR ASSEMBLY
D C TACHOMETER
SPEC 4539G2

HUNT PART
ITEM QTY COMPONENT NUMBER

1.00 1 SPEED SENSOR 4539.01A

2.00 6 BOLT L800A

3.00 6 LOCKWASHER L528

4.00 1 BEARING CAP 4522

5.00 1 FLEXIBLE COUPLING 4642AP03

6.00 1 NUT - BEARING RETAINING 4521.01BP2

F:\WKSHEETS\EVERYONE\RPL\RPLFORM.WK4
 8 7 6 5 4 3 1
2
THE INFORMATION CONTAINED IN THIS DRAWING IS THE SOLE PROPERTY OF REVISIONS
REV. DESCRIPTION DATE APPROVED
HUNT ENGINE, INC. ANY REPRODUCTION IN PART OR WHOLE WITHOUT

THE WRITTEN PERMISSION OF HUNT ENGINE, INC. IS PROHIBITED.

4
D D

2 3 6x 1

C C

B 5 B

ITEM PART OR NOMENCLATURE MATERIAL QTY

NO. IDENTIFYING NO. OR DESCRIPTION SPECIFICATION REQD

PARTS LIST

UNLESS OTHERWISE SPECIFIED CAD GENERATED DRAWING,

HUNT ENGINE, INC.

DIMENSIONS ARE IN INCHES
DO NOT MANUALLY UPDATE
TOLERANCES ARE:

FRACTION S DECIMALS ANGLES A

A .06 .XX .03 .5 APPROVALS DATE
DRAWN ILLUSTRATION
RENEWAL PART LIST
.XXX .005 RWP 1/18/00

CHECKED
SPEED SENSOR ASSEMBLY
SEE PARTS LIST RPL 4539
MATERIAL
VARIOUS RESP ENG

FINISH
MFG ENG
SIZE DWG. NO.
NEXT ASSY USED ON
-- REV.

QUAL ENG B 4539RPL 0

APPLICATION DO NOT SCALE DRAWING SCALE 1/2 CAD FILE: 4539RPL SHEET 1 OF 1
8 7 6 5 4 3 2 1
HÜBNER Digital-Tachos
Drehimpulsgeber / Incremental Encoders
Montage- und Betriebshinweise
Installation and operating instructions

FOG 6 OG 9 POG 9
OG 90 POG 90
POG 9 G

M20x1,5 M20x1,5

Kabel / Cable
∅ 5-7
Kabel / Cable Kabel / Cable
∅ 5-13 ∅ 5-13 EURO-Flansch / EURO flange

OG 8 POG 10 EEx OG 9 FOG 9

POG 100
POG 10 G
FOG 9
+
GT 7

M20x1,5 M20x1,5

Kabel / Cable Kabel / Cable Kabel / Cable Kabel / Cable

∅ 5-9 ∅ 5-13 ∅ 9-13 ∅ 9-13

Wichtige Hinweise Important Notice

■ Digital-Tachos (Drehimpulsgeber) sind opto-elektronische Präzi-
sionsmeßgeräte, die nur von technisch qualifiziertem Personal ge-
handhabt werden dürfen. Sie müssen beim Transport, beim Anbau
und während des Betriebes mit Sorgfalt behandelt werden.
■ Die Geräte werden nach der Qualitätsnorm DIN ISO 9001 ge-
fertigt. EG Konformitätserklärung gemäß Richtlinie 89/336/EWG
Artikel 10 sowie Anhang 1 (EMV-Richtlinie).
■ Digital-Tachos mit EURO-Flansch werden über eine verdrehstei-
fe, flexible Kupplung (z.B. HÜBNER-Federscheiben-Kupplung) an-
getrieben, die sich ohne axialen Druck auf die Welle schieben läßt.
Ist motorseits mit Wellenströmen zu rechnen, darf nur eine isolierte
Kupplung eingesetzt werden.
■ Der Anbau an die Antriebsmaschine muß mit möglichst gerin-
gem Winkelfehler und Parallelversatz erfolgen.
■ Geschirmte Kabel paarig verseilt verwenden. Sie sollten
möglichst in einem Stück und getrennt von Motorkabeln verlegt
werden. Der Kabelschirm wird in der Regel über Kabel-
verschraubung oder Erdklemme mit dem Gehäuse großflächig
verbunden.
Kabelabschluß 120 Ω bei TTL und Sinus.
■ Zur Gewährleistung der angegebenen Schutzart sind nur
geeignete Kabeldurchmesser zu verwenden.
■ Ausgänge nicht auf Betriebsspannung legen:
!!! Zerstörungsgefahr !!!
Spannungsabfälle in langen Leitungen berücksichtigen (Ein- und
Ausgänge).
■ Die zu erwartende Lebensdauer der Geräte hängt von den
Kugellagern ab, die mit einer Dauerschmierung ausgestattet
sind.
■ Digital-Tachos (incremental encoders) are opto-electronic
precision speed measurement devices which must be handled
by skilled personnel and with care during transportation,
mounting and operation.
■ The devices are manufactured according to quality standard
DIN ISO 9001, EU Declaration of Conformity meeting Council
Directive 89/336/EEC art. 10 and annex 1 (EMC Directive).
■ Digital-Tachos with EURO-flange are driven via a torsionally stiff,
flexible coupling (e.g. HÜBNER spring disk coupling) which
should be slid onto the shaft with minimum axial pressure. If shaft
eddy currents occur in the motor shaft, it is recommended an
insulated coupling be used.
■ It should be mounted to the drive machine with a minimum
of angle error and parallel misalignment.
■ Shielded cables should be used with twisted lead pairs. If pos-
sible, they should be placed uninterrupted and individually, but
at a clear distance from the motor cables. Normally the cable
shield is connected to a large surface on the housing via a cable
screw or an earth clamp.
Cable terminating resistance 120 Ω for TTL and sinewave.
■ To maintain the specified degree of protection of the device the
correct cable diameter must be used.
■ Do not connect outputs to supply voltage:
!!! Danger of Damage !!!
Please, pay attention to possible voltage drop in long cable
leads (input and output).
■ The expected operating life of the devices is governed by
the ball bearings, which are manufactured with a permanent
lubrication.
Reg 14/MB 1
 Digital-Tachos / Encoders

Polarität bei Rechtslauf des An-

triebes, Blick auf die A-Seite.
Max. zul. Anbaufehler
Max. admissible mounting errors Polarity for clockwise rotation of
the drive, viewing mountinf face.

Analog-Tacho
GT 7
Analogue tacho
A1: + A2: -

Kohlebürsten / Carbon brushes

ET. 27.1000 4 St. / pieces

∅ d1 H7 ∅ d2 ∅D a b x

FOG 6 60 75 85 3.5 3.5 4 x M5

EURO-Flansch / flange 85 100 115 3.5 3.5 6 x M6

Ausführung Signale Kabel Klemmenkasten Anschlußklemmen Stecker (12 polig) Stecker (10 polig) Ex-Klemmenkasten
Version Signals Cable Terminal box Cable connector Connector (12 pins) Connector (10 pins) Ex-terminal box

E ...
nur K1 + UB rot / red
only K1 ⊥ blau / blue
K1 (A) weiß / white
K2 (B) grün / green
D ...
D ... C

+ UB rot / red
DN ... I ⊥ blau / blue
DN ... C K1 (A) weiß / white
K2 (B) grün / green
K0 (0,1) grau / grey

D ... I + UB rot / red

⊥ blau / blue
D ... CI
K1 (A) weiß / white
D ... TTL K1 (A) braun / brown
D ... R K2 (B) grün / green
K2 (B) gelb / yellow

+ UB rot / red
DN ... I ⊥ blau / blue
K1 (A) weiß / white
DN ... CI
K1 (A) braun / brown
DN ... TTL K2 (B) grün / green
DN ... R K2 (B) gelb / yellow
K0 (0,1) grau / grey
K0 (0,1) rosa / pink

keine Verbindung
no connection Kupplung
2 2
Lötseite /
Bemerkungen nach 8 x 0,14 mm max. 1,5 mm siehe Aufkleber Crimpseite PTB-Nr.
Note 8 x AWG 26 max. AWG 26 look at label Ex-93.C.3136 U
to Viewed from
soldering side
Crimp side

Ausführliche Datenblätter der einzelnen Geräte stellen Detailed specifications of all individual products
wir Ihnen gern zur Verfügung. are available.

HÜBNER ELEKTROMASCHINEN AG
D-10924 Berlin, PB 61 02 71 · D-10967 Berlin, Planufer 92b Technische Änderungen und Liefermöglichkeiten vorbehalten.
Tel.: +49 (0) 30 - 6 90 03 - 0 · Fax: +49 (0) 30 - 6 90 03 - 1 04 Technical modifications and availability reserved.
eMail: marketing@huebner-berlin.de · http://www.huebner-berlin.de Reg 14/MB 1.2 - 01.A.2