MI-65200H

GEI-85150H
ELECTRO-PNEUMATIC
CONTACTORS
TYPE CP2

CONTENTS
Page BASE

DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 ARC
CHUTE
LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
AIR CYLINDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 BLOW–
OUT
INSPECTION AND MAINTENANCE . . . . . . . . . . . . 3 COIL
INTERLOCKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
ARC CHUTES AND ARCING HORNS . . . . . . . . . 3 SHUNT AND
CONTACT
SHUNT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 ASSEMBLIES
MAGNET-VALVE SUPPORTING BLOCK . . . . . . 4
CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
STATIONARY CONTACT SUPPORT . . . . . . . . . . 4
BLOW-OUT COIL ASSEMBLY . . . . . . . . . . . . . . . 4
BASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
MEASURING TIP PRESSURE . . . . . . . . . . . . . . . 5
MEASURING TIP GAP . . . . . . . . . . . . . . . . . . . . . . 5
TIP ALIGNMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
DISASSEMBLY OF CONTACTOR . . . . . . . . . . . . . 5
ASSEMBLY OF CONTACTOR . . . . . . . . . . . . . . . . . 5
TESTING OF CONTACTOR . . . . . . . . . . . . . . . . . . . 7
MAGNET VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 INTERLOCK
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 AIR
CYLINDER
MAGNET-VALVE DATA . . . . . . . . . . . . . . . . . . . . . . 8 MAGNET
INSPECTION AND MAINTENANCE . . . . . . . . . . 8 VALVE

FIG. 1. TYPICAL CP2 CONTACTOR. E-9172A.

DESCRIPTION
NOTE: Contactor Models 17CP2-W11, -BE3,
Type CP2 contactors are electro-pneumatic devices -BD3, -BH9 and -BH11 have two magnet valves
which connect or disconnect electrical circuits. applied. The magnet valve mounted in the nor-
mal position controls the flow of air to the oper-
ating air cylinder in the same manner as for all
When electric power is applied to the contactor mag- other models. However, the second magnet
net-valve coil, air flows to the air cylinder and causes the valve is applied on these models to open the
contactor to close. Current then flows through the main contactor tips faster. It is energized at the same
contacts to complete an electrical circuit. When power is time as the first and although it does not supply
removed from the magnet-valve coil, air pressure in the air, it does help exhaust air from the operating
cylinder is released and the contactor opens to break cylinder when both magnet valves are de-ener-
the circuit. gized.

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.
MI-65200H
GEI-85150H, ELECTRO-PNEUMATIC CONTACTORS, TYPE CP2

The CP2 contactor consists of the following main
parts: an air cylinder, main contacts, an arc chute, and a
magnet valve (Fig. 1). In most cases, low-voltage con-
tacts and interlocks are mounted on the contactor. For
instructions on the interlocks, see the individual inter-
lock publication.
DATA
Table 1 gives the tip gap, wipe (overtravel), pressure
of the contacts, and the model of the magnet valve for
each form of the CP2 contactor.
For data on the magnet valves, see MAGNET
VALVES section in this publication.
LUBRICATION
AIR CYLINDERS
Once a year, add several drops of GE-D6B11B oil to
the cyliders through the oil holes or through the cylinder
heads. Contactors manufactured after May, 1962 are
assembled with filled Teflon* packings in the cylinders.
Filled Teflon packings require no lubrication; however,
they will operate satisfactorily if lubricated. If doubt ex-

TABLE 1. TYPE CP2 CONTACTORS.

Tip Gap Wipe

Form In 32nd’s of In 32nd’s of Pressure (lb.) Model
an Inch an Inch Initial Final Magnet Valve
min. max. min. max. min. max. min. max.
T9 31 35 28 36 10 19 23 37 17MV38A1
V3 31 35 28 36 10 19 23 27 17MV38A6
V9 31 35 28 36 10 19 23 27 17MV38A1
W11 18 22 28 36 10 19 23 37 17MV38A12
AK3 18 22 28 36 10 19 23 37 17MV38A6
AK8 18 22 28 36 10 19 23 37 17MV38A8
AM3 18 22 28 36 10 19 23 37 17MV38A6
AN3 18 22 28 36 10 19 23 37 17MV38A6
BC3 18 22 28 36 10 19 23 37 17MV38A6
BC8 18 22 28 36 10 19 23 37 17MV38A8
BC9 18 22 28 36 10 19 23 37 17MV38A1
BC11 18 22 28 36 10 19 23 37 17MV38A12
BC12 18 22 28 36 10 19 23 37 17MV34B14
BD3 18 22 28 36 10 19 23 37 17MV38A6
BE3 18 22 28 36 10 19 23 37 17MV38A6
BF3 18 22 28 36 10 19 23 37 17MV38A6
BH9 18 22 28 36 10 19 23 37 17MV38A1
BH11 18 22 28 36 10 19 23 37 17MV38A12
BJ3 18 22 28 36 10 19 23 37 17MV38A6
BM11 18 22 28 36 10 19 23 37 17MV38A12
BN11 18 28 36 10 19 23 37 17MV38A12
BR3 18 22 28 36 10 19 23 37 17MV38A6
BS3 18 22 28 36 10 19 23 37 17MV38A6

*Product of E.I. duPont de Nemours Co.

2

ELECTRO-PNEUMATIC CONTACTORS, TYPE CP2, GEI-85150H
ists as to the type of packing used, lubricate the cylin-
ders.
NOTE: Contactors manufactured after January,
1964 do not have an oiler. Oil is not required for
the Teflon packing.
At overhaul:
1. Immerse the piston assembly in GE-D6B11B hy-
draulic oil.
2. Remove the piston assembly from the oil and
quickly insert the assembly in the cylinder.
3. Operate the piston up and down to distribute the
oil over the cylinder walls.
If the packing shows signs of wear or deterioration or if
blowby exists, replace the packing.
After reassembly, check for air leaks by applying
soapy water at the joints and pipe connections.
INSPECTION AND MAINTENANCE
The following inspection should be made to determine
when the main contacts, bushings, or contact arm
should be replaced to give maximum contactor life.
1. Close the contactor and insert a 9/16-in. square
block between the piston rod and the cylinder
head.
2. Open the contactor so the piston rod is held up
from the cylinder head by the 9/16-in. block. The
main contacts should touch at some point along
their surfaces.
3. Replace the contact tips if the main contacts do
not touch. If the contact tips do not touch but are
not excessively burned, check the bushings or
contact arm for excessive wear. The condemn-
ing limit for either is 3/32 in. “free movement” of
the main contact tip.
4. If the shunts drag on the operating lever when
the contact tips just touch, the main contacts
must be replaced.
MI-65200H
INTERLOCKS (When Applied)
Low-voltage control interlocks permit a preliminary
check for proper positioning of contactors or relays be-
fore the application of high-voltage electrical power.
When the contactor picks up, the normally closed (NC)
interlock contacts will open and the movable fingers will
close the normally open (NO) contacts. Ensure all mov-
able interlock fingers touch the stationary contacts at
the same time and properly wipe-in (overtravel). Adjust
overtravel of interlock fingers as follows to values given
in publication for type interlocks being serviced.
1. Adjust the normally closed interlock contacts
with the main tips open. Adjust the screw contact
tips so that they just touch the movable contact
fingers.
2. From this point, advance the screw contact, to
the overtravel value given in the publication for
the interlock being serviced.
3. Close main contact tips fully by applying air pres-
sure.
4. Repeat adjustment procedure in Steps 1 and 2
for normally open interlock contacts.
ARC CHUTES AND ARCING
HORNS
1. Inspect the arc chute. Replace or repair the
chute if the side plates are burned 3/4 through. If
the asbestos-board end pieces are burned close
to the screws, replace the end pieces. Replace
the lava inserts when used, if burned 3/4
through.
2. Inspect the arcing horns. If they are burned back
more than 1/8 in. from the edge, replace them.
3. Inspect the clearance between the tip of the arc-
ing horn and the movable contact tip for 3/16 to
5/16 in.
SHUNT
Inspect the shunt and its terminals for wear, fraying,
discoloration or stiffness caused by heat. Check the ter-
minal nuts for proper torque. See appropriate Renewal
Parts Bulletin for proper replacement shunt.
3
MI-65200H
GEI-85150H, ELECTRO-PNEUMATIC CONTACTORS, TYPE CP2

FIG. 2. MEASURING THE INITIAL PRESSURE. E-3513A.

CAUTION: If a high resistance develops at ei- NOTE: Step 2 will not apply to contactors man-
ther end of the shunt, current will bypass the ufactured after January, 1964. These contactors
shunt and flow through the air cylinder and will not have oilers in the air cylinders because
damage the cylinder packing. they do not require oiling.

MAGNET-VALVE SUPPORTING STATIONARY CONTACT SUPPORT

BLOCK
1. Inspect the contact support for cracks or discol-
1. Clean the supporting block thoroughly and blow
oration caused by heat. If discoloration or cracks
it dry.
are found, replace the contact support.
2. Inspect the fiber tubes to be sure they are clean
inside. 2. Inspect the tapped holes in the contact support
for burring, stripping or other damage to the
3. Inspect the rubber gaskets between the block threads. If the threads are damaged and retap-
and cylinder. Replace them if they have hard- ping will not correct the condition, replace the
ened. contact support.

4. Replace the supporting block if any cracks are 3. Do not remove the tin plating from the tinned con-
found between the fiber tubes and the mounting tact surfaces.
studs.
BLOW-OUT COIL ASSEMBLY
CYLINDER

1. Inspect the cylinder face and the cylinder bore for
scratches or gouges. If the scratches or gouges
cannot be removed with crocus cloth, replace
the cylinder.
2. Inspect the oiler and the oiler hole for free flow of
lube oil to the parts.
1. Inspect the blow-out coil core insulation. If the in-
sulation is charred or burned away, remove and
replace the core assembly.
2. Inspect the blow-out coil and lead for signs of
mechanical failure. Clean and paint the turns of
the coil with GE-A15B17A varnish.

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ELECTRO-PNEUMATIC CONTACTORS, TYPE CP2, GEI-85150H
NOTE: On some CP2 contactors, the blow-out
coils are tin plated and require cleaning only;
do not paint tin plated coils. After cleaning, the
turns of the blow-out coil should be checked to
be sure there is at least a 0.005-in. clearance be-
tween the sides of the turns.
3. Inspect the insulation on the blow-out coil lead. If
the insulation is brittle or damaged, reinsulate
the lead.
BASE
1. Clean the base block thoroughly.
2. Inspect the base for cracks or other damage. If
the base is cracked or damaged, replace the
base.
MEASURING TIP PRESSURE
1. Measure the tip pressure as shown in Fig. 2. See
pressure values under Data section. Insert a thin
piece of paper between the contact arm and the
inner stop.
2. Attach a spring balance to the movable contact
tip. The balance must be capable of accurately
measuring the values give in Table1.
3. Read initial pressure on the spring balance at the
instant the paper can be removed. Low initial
pressure indicates a defective contact pressure
spring, worn spring seat or worn stop.
4. Measure the final tip pressure by pulling the
spring balance until the contact arm hits the outer
stop. The reading when the arm hits the stop is
the final pressure. Low final tip pressure indi-
cates a defective contact pressure spring.
MEASURING TIP GAP
Measure the tip gap across the open contacts at the
point where the tips would first touch when closed. See
Table 1 for tip gap values.
TIP ALIGNMENT
Allowable side to side tip misalignment is 1/16-in.
overhang of the movable contact tip on either side of the
MI-65200H
stationary contact tip. Heels of the contact tips may also
have a 1/16-in. overhang. One tip may protrude beyond
the other by this amount.
DISASSEMBLY OF CONTACTOR
(See Fig. 3)
Disassemble the contactor as follows:
1. Remove the stationary and movable portions of
the interlock.
2. Remove the arcing-horn assembly from the cyl-
inder casting.
3. Remove the magnet valve from the supporting
block. See MAGNET VALVES section for repair
of magnet valves.
4. Disconnect the shunts from the terminals.
5. Remove the operating assembly from the cylin-
der and piston rod.
6. Disassemble the contact tip, shunt and contact-
arm assembly and remove the operating arm.
7. Remove the cylinder head from the cylinder
body.
8. Disassemble the piston-rod assembly.
9. Remove the piston rod from the cylinder head.
10. Disassemble the cylinder from the contactor
base.
11. Remove the magnet-valve supporting block as-
sembly and the terminal from the cylinder.
12. Remove the stationary contact support from the
contactor base and disassemble the support.
13. Scrap all cotter pins.
ASSEMBLY OF CONTACTOR
Assemble the contactor as follows:
1. Assemble the contact tip and the arcing horn. At-
tach this subassembly to the stationary contact
support. If the core has been removed, reas-
semble it to the blow-out coil.
2. Assemble the stationary contact support (with
the contact and arcing horn) to the contactor
base.
5
MI-65200H
GEI-85150H, ELECTRO-PNEUMATIC CONTACTORS, TYPE CP2

REF. DESCRIPTION REF. DESCRIPTION REF. DESCRIPTION

1 ARC CHUTE 7 FOLLOWER 13 SHUNTS
2 CYLINDER 8 PACKING 14 CYLINDER HEAD ASSEMBLY
3 CYLINDER CAVITY 9 PISTON 15 MOUNTING SCREWS (4)
4 GASKET 10 SEALING WASHER 16 MAGNET VALVE
5 COTTER PIN 11 SPRING
6 PISTON–ROD NUT 12 PISTON ROD

FIG. 3. VIEW OF DISASSEMBLED CP2 CONTACTOR. E-3110B.

3. Assemble the magnet-valve supporting block
assembly and terminal to the cylinder.
4. Insert the piston rod through the center hole of
the cylinder head.
5. Assemble the cylinder head assembly as fol-
lows:
a. Assemble the spring, gasket, piston, piston
packing and follower, slotted nut and a new
cotter pin to the piston rod.
b. Immerse the piston assembly in GE-D6B11B
oil.
c. Remove the piston assembly from the oil and
quickly insert the oil-covered assembly into
the cylinder.
d. Operate the piston up and down to distribute
the oil over the cylinder walls.
e. Assemble the piston rod and cylinder head
assembly to the cylinder.
NOTE: Contactors manufactured after May,
1962 are assembled with filled Teflon packings
in the cylinders. Filled Teflon packings require
no lubrication; however, they will operate satis-

6

ELECTRO-PNEUMATIC CONTACTORS, TYPE CP2, GEI-85150H
factorily if lubricated. If doubt exists as to the
type of packing used, lubricate the cylinders.
6. Assemble the cylinder to the contactor base.
7. Assemble the contact tip and shunts to the con-
tact arm.
8. Assemble the contact arm to the operating arm
and insert the compression spring.
9. Assemble the operating arm and contact-arm
assemblies to the piston rod. Use new cotter pins
in the linkage pins.
10. Connect the shunts to the terminal. Do not align
terminal end of shunts with Y projections, but
bring them up parallel with each other to movable
contact terminals. This will assure proper clear-
ance of shunts with those of adjacent contactors;
otherwise, short circuits can develop. Do not re-
move the tin plating on the terminal when apply
shunts.
CAUTION: Improper application of shunts or
bending of shunt terminals could cause shorting
or arcing on the contactor or between adjacent
contactors. Replacement shunts must be same
physical dimensions as originally applied.
11. Assemble the magnet valve to the supporting
block.
12. Assemble the supporting block and arcing-horn
assembly to the cylinder head.
13. Assemble the stationary portion of the interlock
to the support, and the movable portion to the op-
erating arm.
14. Adjust the interlocks as outlined in the individual
interlock publication.
TESTING OF CONTACTOR
Test as follows:
1. With contactor base mounted vertically with con-
tactor tips up, check the contactor for sluggish
operation.
MI-65200H
FIG. 4. AIR SUPPLY SYSTEM FOR TESTING
CP2 CONTACTOR. E-6661A.
a. Connect the magnet valve to a 70-pound air
supply as shown in Fig. 4. Apply soap bubble
test to verify no leakage around cylinder and
magnet valve connections. Verify leakage
past packing is less than 40 cu. in./min.
b. Depress the magnet-valve armature to close
the contactor. The contactor should close im-
mediately.
c. Release the magnet-valve armature to open
the contactor. The contactor tips should part
and come to a fully open position without hes-
itation.
d. On the contactors that use two magnet
valves, check for air leakage in the tubing
connection between the magnet-valve
mounting and the cylinder body.
2. Check the tip alignment. If necessary, loosen the
screws holding the stationary support and the
cylinder assembly to the base block and move
the assemblies until the tips are properly aligned.
See the limits under Tip Alignment in the IN-
SPECTION AND MAINTENANCE section.
3. Measure the tip pressure as outlined under Mea-
suring Tip Pressure in the INSPECTION AND
MAINTENANCE section.
4. Operate the contactor several times and see that
the main contacts touch before the normally
open interlock contacts touch, and the normally
closed interlock contacts open before the main
contacts touch.
7
MI-65200H
GEI-85150H, ELECTRO-PNEUMATIC CONTACTORS, TYPE CP2

FIG. 5. MV38 MAGNET VALVE. E-10647.

MAGNET VALVES
DESCRIPTION

The Type MV38 Magnet Valves are used on the CP2

contactor. This valve controls the air flow to the air cylin- FIG. 6. SECTIONAL VIEW OF MAGNET VALVE.
der which, in turn, controls the action of the contactor. E-10645.

A magnet valve has the following main parts: frame,

coil, armature, valve body, valve, valve stem and termi- TABLE 2. TYPE MV38 MAGNET VALVE.
nals. These main parts are assembled with others to Resistance Amps to
make the complete valve assembly as shown in Figs. 5 at 25 C Volts Operate
and 6. Form (ohms) Continuous at 90 psi

MAGNET-VALVE DATA 1 317 88 0.108

2 130 55 0.181
Table 2 shows the coil resistance, volts continuous, 4 30.7 12 0.480
and amperes required to operate the various forms of 6 732 135 0.069
MV38 magnet valves. 8 2850 270 0.036
12 82 44.6 0.206
INSPECTION AND MAINTENANCE
Amperes required to operate at 70 psi are 91 of am-
The following procedure will assist in the inspection peres required to operate at 90 psi.
and maintenance of the magnet valve (Figs. 6 and 8). Amperes required to operate when mounted upside
down increase 15.
1. Test the magnet-valve operation by depressing
the armature on the top of the magnet valve. If Application at more than 90 psi is practical only under
the valve sticks, it must be cleaned. special conditions.

8

ELECTRO-PNEUMATIC CONTACTORS, TYPE CP2, GEI-85150H
LAPPING COMPOUND ON VALVE
DRAFTING PENCIL CHUCK
FIG. 7. SEATING INLET VALVE. E-23308.
2. Test for leaks by applying soapy water to the pipe
connections and exhaust port while air pressure
is on the valve. Tighten all leaky connections. A
small amount of leakage through the exhaust
port is acceptable if the locomotive leak-down
test can still remain in limits. If excessive leakage
is found, disassemble the valve for cleaning.
3. Disassemble the valve for cleaning as follows:
a. Remove the cap plug (9) to release the inlet
valve (6) and spring (7).
b. Remove the armature guide (2) and armature
(1) to release the exhaust valve stem (11).
c. Remove the retaining ring (12) with snap ring
pliers to permit removal of the valve coil (15).
4. Clean the ports, valve seats, valve stem and
spring with a suitable solvent.
5. If the valve stem does not seat properly, “lap in”
the valve stem with medium and fine lapping
compound or graphite and oil. After the valve
stem has been properly seated, clean the ports
to remove the compound.
A convenient method of supporting the inlet
valve for lapping (Fig. 6, Item 6) is to hold it in the
chuck of a drafting lead holder (Fig. 7).
6. Reassemble the valve as follows:
a. Install the inlet valve, spring and cap plug.
b. Install the valve body, coil and retaining ring.
MI-65200H
FIG. 8. VALVE TRAVEL. E-10646B.
WARNING: Cleaning solvents may be toxic
and/or inflammable. They can cause serious
or fatal injury if used without precautions.
For safety:
1. Do not inhale solvent fumes.
2. Use solvents only in adequately ventilated
area.
3. Avoid contact of the solvent with the skin.
4. Do not expose solvent to flame or sparks.
5. Observe caution statements used by the
manufacturer of the solvent.
c. Install the exhaust-valve stem, the armature
and the armature guide.
7. The exhaust-valve stem travel should be
checked with a rectangular limit gage (GE Part
41A323657P1, Fig. 9). Remove the armature
and the armature guide from the valve. Measure
the distance the exhaust-valve stem extends
above the top of the valve body by applying gage
as shown in Fig. 9. The extension should be
0.104-in. as measured with the 0.104-in. section
on the limit gage without depressing stem so inlet
valve is in contact with bottom surface of valve
seat. Depress the valve stem with the 0.052-in.
section of the limit gage. The exhaust-valve stem
9
MI-65200H
GEI-85150H, ELECTRO-PNEUMATIC CONTACTORS, TYPE CP2

GAGE

EXHAUST
VALVE STEM

CORE

COIL

FIG. 9. METHOD OF CHECKING VALVE STEM

TRAVEL WITH GAGE, PART 41A323657P1 IN
PROPER PLACE (VALVE DE-ENERGIZED).
E-17789A.

should seat on top surface of the valve seat

thereby indicating proper 0.052-in. travel. Now
measure the valve with 0.032-in. section of the
limit gage to determine if wear is approaching
maximum limit. The exhaust-valve stem should
remain seated. If the 0.032-in. section does not
seat the valve stem, wear is excessive and a new
valve stem must be installed as follows: See Fig.
6 for part references. FIG. 10. VALVE SEAT LOCATION. E-10648A.

a. Disassemble the valve and seat the new ex-
haust-valve (11) on the top surface of valve
seat (17). Cut off the top of the stem (11) until
it extends 0.052 in. above the top of the valve
body as measured with the 0.052-in. section
of the limit gage when in contact with top of
the valve body (Fig. 8).
b. Insert the inlet-valve stem into the hole at the
end of the exhaust-valve stem (Fig. 9). Install
the inlet-valve spring and cap plug. Measure
the distance from the top of the exhaust stem
to the top of the valve body with the 0.104-in.
section of the limit gage. If the stem extends
more than 0.104 in. above the valve body, cut
off the end of the stem until 0.104 in. has been
obtained.
c. Reassemble the valve after the stem travel
has been checked and found to be correct.
8. If the valve seats are excessively scored or worn,
install new seats. The valve seat is pressed into
the valve body with a 0.001 to 0.003-in. interfer-
ence fit. Therefore it must be pressed out from
the valve body end. To gain access to the valve
seat, disassemble the valve. Press out the old
seat and press a new valve seat into place to the
dimensions shown in Fig. 10. Match the hole in
the seat with the outlet port of the valve body.

10
 MI-65200H
ELECTRO-PNEUMATIC CONTACTORS, TYPE CP2, GEI-85150H

NOTES

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MI-65200H
GEI-85150H, ELECTRO-PNEUMATIC CONTACTORS, TYPE CP2

GE Transportation
Systems
2901 East Lake Road
Erie, Pennsylvania 16531
NEW 05–85, CON PRINTED
IN
U.S.A.
E

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