GEK-91664

MOTORIZED WHEEL
AIRFLOW TESTING

This publication provides Motorized Wheel airflow
testing procedures.
During normal truck operation the Motorized
Wheels, alternator and electrical control system reĆ
quire a constant supply of forced cooling air to prevent
overheating. A forced cooling air supply on the truck is
designed to supply this cooling air.
The efficiency of a forced air cooling system in any
given application is limited by operating conditions and
by the level of maintenance of system components.
The following factors can negatively affect the air supĆ
ply system performance:
1. Airflow restrictions the air duct system and in the
equipment receiving the cooling air.

2. Ambient air density at the operating site.

The source of the cooling air may be a blower fan
mounted on the alternator shaft, a separate compoĆ
nent belt driven by the alternator or a separate blower
motor unit. The complete air supply system including
ductwork may be an assembly of parts fabricated by
several manufacturers.
Motorized Wheel insulation life varies with the seĆ
verity of the application, environmental conditions and
vehicle operating practices. To obtain maximum MotorĆ
ized Wheel insulation life, the amount of cooling air
should meet the minimum values in Table 1.
3. Lack of maintenance of the forced air supply
system to prevent air leakage, air blockage and
belt slipping (where applicable).
To determine whether adequate airflow is present in
the Motorized Wheels, a simple, effective test is proĆ
vided in this instruction. This test will indicate the actual
Motorized Wheel airflow regardless of the particular veĆ
hicle type, brake rigging or hubcaps installed at the
time of the test. Airflow test results are corrected to reĆ
flect current air density and engine rpm.

When airflow is measured, it is recorded in both cuĆ

TABLE 1 bic feet per minute (cfm) and in inches of water. The
amount of airflow in inches of water is the pressure difĆ
Motorized Wheel Required Airflow
ferential across the motor from the the axle box to the
GE772 1680 cfm motor's commutator chamber and is read directly from
GE776 2000 cfm the gauge. The amount of airflow in cubic feet per minĆ
GE787 2600 cfm ute is determined using the pressure differential figure
and the pressure/volume curves in Figs. 11 through 13.
GE788 2600 cfm
Curves for all current production Motorized Wheels are
GE791 2000 cfm provided.

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 beyond any contractual obligation.
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-91664, MOTORIZED WHEEL AIRFLOW TESTING
GE776 AND GE791 - OTHERWISE SAME AS G1.
FIG. 1. DIFFERENTIAL PRESSURE MEASUREMENT FIXTURE (41C636650, CHG., A) E-33552.
To determine pressure differential, a pressure differĆ
ential measurement fixture, 41C636650, is used. See
Fig. 1. When performing the test, the Motorized Wheel
acts as a measurement device.
Axle box pressure is directly related to pressure difĆ
ferential on the Motorized Wheels of a given truck conĆ
figuration. After the pressure differential is recorded in
inches of water, axle box pressure should also be reĆ
corded. This will establish a specific axle box pressure
for the pressure differential for the truck being tested.
Future axle box pressure tests, performed at regular
test intervals, can then be used to periodically monitor
airflow. Any significant change in axle box pressure
2
GE787 AND GE788 -
OTHERWISE SAME AS G2.
represents a change in airflow and could indicate an air
supply system fault. Corrective measures should be
taken before serious equipment damage occurs.
TESTING INTERVALS
It is recommended that this airflow test be conĆ
ducted to verify adequate Motorized Wheel airflow and
to establish correct axle box pressure. Perform the test
initially on new trucks before placing them into service
and on older trucks at the first convenient maintenance
period. The test should be repeated whenever the
cooling air system has been repaired or whenever a
problem is suspected.
 MOTORIZED WHEEL AIRFLOW TESTING, GEK-91664
FIG. 2. MAGNEHELIC PRESSURE GAUGE
(41A239756, CHG. B). E-33553.
After the completion of airflow tests, periodically
check the integrity of the cooling air system by performĆ
ing an axle box pressure test according to the interval in
the Maintenance Table in the Planned Maintenance
book, GEK-75889. Compare the new axle box presĆ
sures to previous axle box pressures. If a significant difĆ
ference is noted, check for a problem in the air system
(air ducts, hubcaps, brake rigging, etc.)
NOTE: Axle box pressure, pressure differential
readings and airflow readings are all affected by
both engine speed and air density. Maintenance
records containing these data should also inĆ
clude both engine speed and air density. PresĆ
sure and airflow readings should always be conĆ
FIG. 4. PRESSURE TAP HOLDER (41B537555, CHG. A). E-33555
FIG. 3. FIXTURE MAGNET (41A239741, CHG. 0).
E-33554.
verted to standard air values and adjusted for
any rpm differences for comparison purposes.
TEST EQUIPMENT
The test equipment required to perform this airflow
test is available in kit form as follows:
41C636650G1 - GE772
41C636650G2 - GE776 and GE791
41C636650G3 - GE787 and GE788
They can be ordered from your normal source of GE
parts and consists of the following major components:
1. A differential pressure measurement fixture,
Fig. 1.
2. A magnehelic pressure gauge, Fig. 2. This
gauge reads the difference between two input
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GEK-91664, MOTORIZED WHEEL AIRFLOW TESTING

FIG. 5. RUBBER TUBING (41A239736, CHG. A).

E-33556.
pressures. It can also be used for reading axle
box pressure.

3. A magnet which holds the pressure fixture in

FIG. 7. AXLE BOX PRESSURE TAP
place, Fig. 3.
(41A239793, SH. 7, CHG. 0). E-33558.
4. A pressure tap holder which positions the low
pressure tap inside the commutator chamber, 3. Drill a 0.62 in. diameter hole in the wall of the
Fig. 4. hubcap (if necessary) and bring out the other
end of the tubing from the fixture. Attach the end
5. A 50 foot length of latex rubber tubing, Fig. 5 of this tubing to the low pressure port on the
magnehelic gauge as shown in Fig. 6.
TEST SETUP
4. Drill and tap a 0.125 NPT hole in the center of the
1. Remove the hubcap from the Motorized Wheel axle box access cover. Check to insure that the
to be tested and attach the test fixture to the moĆ axle box cover seal is good.
tor as shown in Fig. 1.
5. Mount a second pressure tap onto the axle box
2. Attach one end of a length of tubing to the end access cover in the tapped hole.
of the pressure tap located in the commutator
chamber. 6. Attach one end of a piece of tubing to the axle
box pressure tap as shown in Fig. 7. Attach the
other end of this tubing to the high pressure port
of the gauge as shown in Fig. 6.

7. Install hubcaps on both wheels and ensure that

the axle box cover and cover gasket are secure
and all duct work is hooked up and free of holes,
etc.

TEST PROCEDURE

This test must be made with both Motorized Wheel

hubcaps installed. Also, both hubcaps must be identiĆ
cal, otherwise airflow will be unevenly distributed beĆ
tween the two wheels.

1. Start the engine.

FIG. 6. CONNECTIONS TO GAUGE 2. Run the engine up to full load speed and hold.
(41A239793, SH. 7, CHG. 0). E-33557. See Table 2. Verify engine rpm with a hand
tachometer.

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 MOTORIZED WHEEL AIRFLOW TESTING, GEK-91664

TABLE 2 Proceed with the test. Note and record the enĆ
gine test speed. Then refer to WHEN ENGINE IS
Engine RPM NOT AT FULL LOAD SPEED.
Caterpillar 1800
8. Return the engine to idle and shut it down.
Detroit 1900
Cummins 2100 9. Determine air density. Refer to TO DETERMINE
AIR DENSITY section.
NOTE: If the test is run at other than full load
10. Determine the airflow. Refer to TO DETERMINE
speed, airflow calculations will not be accurate.
AIRFLOW section.
Proceed with the test. Note and record the enĆ
gine test speed. Then refer to WHEN ENGINE IS 11. Record the test results for both motors, engine
NOT AT FULL LOAD SPEED. speed, air density and axle box pressure in the
truck's Maintenance Log. The test results
3. Note and record the reading on the magnehelic should be the same for both motors. If not, loĆ
gauge cate and correct the problem.

4. Return the engine to idle and shut it down. EnĆ TO DETERMINE AIR DENSITY
gine idle speed should be approximately 750
rpm. Ambient air density will affect the pressure readĆ
ings. At high altitudes, the air usually has lower density
5. Disassemble the test set-up and set up to test than at lower altitudes; that is, the higher the altitude,
the other wheel. Repeat steps 1 through 4. the lower the air density. Since air at a lower density
weighs less per cubic foot than air at a higher density, it
6. Using the same gauge, set up to take axle box will exert a lower pressure on the gauge for the same
pressure readings, Fig. 8. cfm of airflow as that of a higher density. Conversely, air
at a higher density weighs more per cubic foot and will
7. Start the engine, run it up to full load speed and exert a higher pressure on the gauge for same cfm of
take the reading. air as that of a lower density.

NOTE: If the test is run at other than full load In order to determine airflow and to use the airflow
speed, airflow calculations will not be accurate. charts in this instruction which are in part scaled in deĆ
grees of air density, you must first determine air density.
Use the following procedure:

1. Contact the local airport to determine the baroĆ

metric pressure. (Assume 28 in. of mercury for
this example. This barometric pressure is alĆ
ready corrected to sea level when reported by
the airport. Hence, it must be adjusted for the
difference in altitude between sea level and the
test site.)

2. Determine elevation in feet above sea level. (AsĆ

sume altitude is 6000 ft. as an example.)

3. Determine pressure in inches of mercury. Go to

FIG. 8. CONNECTIONS TO GAUGE FOR AXLE Fig. 9. Interpolate that for 6000 ft. altitude, the
BOX PRESSURE TEST MEASUREMENTS corresponding pressure in inches of mercury is
(41A239793, SH. 7, CHG. 0). E-33660 24.0.

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GEK-91664, MOTORIZED WHEEL AIRFLOW TESTING
4. Adjust air pressure for altitude by the following
calculation:
IN. OF MERCURY X 24 = IN. OF MERCURY CORRECTED TO
CONSTANT A SPECIFIC ELEVATION
28 X 24 = 22.45 iinches mercury at that
29.921 elevation.
(29.921 is a constant)
5. Determine temperature in degrees Fahrenheit.
(This temperature had been chosen as 80 deĆ
grees as an example.)
6. Calculate air density from Fig. 10. (Interpolate
air density as 0.055 lb/cu.ft. from intersection of
80 degrees and 22.45 inches of mercury.
7. Read the pressure drop between the axle box
and the frame head. (Assume 4 in. water).
8. Use Figs 11, 12 and 13 to determine airflow. For
example, using Fig. 13, interpolate 4 in. water
drop and 0.055 air density as 2640 cfm.
TO DETERMINE AIRFLOW
Once the air density is determined, the airflow can
be found by using the appropriate airflow chart. Refer
to Figs. 11, 12 and 13. Proceed as follows:
1. Find the appropriate air density line at the right
side of the chart.
2. Using the pressure reading from the gauge, loĆ
cate the correct pressure line at the left side of
the chart.
3. Move horizontally from the left on the pressure
line until it intersects with the density line. Then,
from that intersection, move directly downward
to the airflow scale and read the airflow in cfm.
4. After the airflow is determined for one Motorized
Wheel, move the pressure differential fixture to
the other wheel and repeat these procedures.
WHEN ENGINE IS NOT AT
FULL-LOAD SPEED
If the test must be run with the engine other than
full-load speed, the test results (pressure readings)
6
must be corrected to determine what the pressure
would be at the full-load speed. This procedure is as
follows:
1. Observe and record the engine speed during
the test.
2. Determine what the full-load engine speed
should be.
3. Determine the Speed Factor, which is the ratio
of full-load engine speed to engine test speed
squared. Calculate the Speed Factor by perĆ
forming the following equation:
Full-Load Speed 2
Speed Factor (SF) =
Test Speed
4. Calculate the corrected pressure by performing
the following equation:
Full-Load Pressure = Actual Pressure X Speed Factor
5. refer to TO DETERMINE AIRFLOW using the
above calculated pressure.
MAINTENANCE TIPS
The following items will help to maintain the forced
cooling air system in good condition.
1. Keep a record of airflow measurements. This
will quickly indicate when a marked reduction in
airflow occurs and the problem can be corĆ
rected before serious damage occurs.
2. Look for air leaks in the ducting system. LeakĆ
age can be caused by:
a. Torn Flexible Ducting
b. Loose Fittings
c. Missing Seals
d. Dented Or Ruptured Metal Ducting
3. Look for any blockage in the ducting system. If
excessive lengths of flexible ducting are used,
the ducting can sag in certain places, allowing
dirt to collect which will block airflow.
4. On belt driven blowers, check for loose belts.
Slipping belts cause reduced blower output.
 MOTORIZED WHEEL AIRFLOW TESTING, GEK-91664
5. The 7A13 blower uses different pulley ratios for
different engines. Check for proper pulley size
when an engine is changed out.
6. Excessively dirty air can cause fan blade eroĆ
sion. This will gradually reduce fan output.
7. Check the hubcaps. They should be identically
matched to insure that airflow will be evenly disĆ
tributed between the two Motorized Wheels. InĆ
sure that hubcap openings are not blocked and
that hubcap screens are freeflow to minimize
the tendency for blockage. If the hubcaps are alĆ
lowed to become blocked, pressure in the MoĆ
torized Wheels and in the axle box will increase
and airflow will be reduced.
EXAMPLES OF AIRFLOW TESTS
Example No. 1
Assume that the following information is found durĆ
ing an airflow test.
1. The pressure differential reading on the gauge
across a GE776 Motorized Wheel was 3.4 in.
water.
2. Engine speed during the test was 2340 rpm, no
load wide-open throttle. Full-load engine
speed is set at 2100 rpm.
3. Ambient temperature was 60_ F and the baroĆ
metric pressure was 29.25 in.
To determine the airflow through the Motorized
Wheels with these conditions, perform the following:
1. Determine the Speed Factor (SF) by squaring
the ratio of full-load engine speed to test
speed:
Full-Load Speed 2
Speed Factor (SF) =
Test Speed
2100 2
Speed Factor (SF) =
2340
Speed Factor (SF) = 0.8054
2. Determine the pressure drop at full load:
Full-Load Pressure = Recorded Pressure X Speed Factor
Full-Load Pressure = 3.4 X 0.8054
Full-Load Pressure = 2.75
3. Determine the air density from the chart in Fig.
10. The intersection of the 60_ F temperature
line and a line representing 29.25 barometric
pressure corresponds to the line indicating
0.075 lb./cubic feet air density.
4. Determine the airflow from the GE776 airflow
chart in Fig. 11. The intersection of the 2.75
pressure line and the 0.075 air density line is opĆ
posite the 1800 cfm airflow indication.
Conclusion - The forced air supply system is supĆ
plying 1800 cfm cooling air which is not enough for
GE776 Motorized Wheels.
Example No. 2
Assume that the following information is found durĆ
ing an airflow test at an altitude of 15,000 feet:
1. The pressure differential reading on the gauge
across a GE776 Motorized Wheel was 1.4 min.
water.
2. engine speed during the test was 1900 rpm.
Full-load engine speed is set at 1900 rpm.
3. Ambient air temperature was 100_ F and the
barometric pressure was 17.00 in.
To determine the airflow through the Motorized
Wheels with these conditions, perform the following:
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GEK-91664, MOTORIZED WHEEL AIRFLOW TESTING

1. Determine the Speed Factor (SF) by squaring Full-Load Pressure = 1.40

the ratio of full-load engine speed to test
speed: 3. Determine the air density from the chart in Fig.
10. The intersection of the 100_ F temperature
line and a line representing 17.00 barometric
Full-Load Speed 2 pressure corresponds to the line indicating
Speed Factor (SF) =
Test Speed 0.040 lb./cubic feet air density.

1900 2 4. Determine the airflow from the GE776 airflow

Speed Factor (SF) = chart in Fig. 11. The intersection of the 1.40
1900
pressure line and the 0.040 air density line is
Speed Factor (SF) = 1.00 approximately 1780 cfm.

Conclusion - The forced air supply system is supĆ

2. Determine the pressure drop at full load:
Full-Load Pressure = Recorded Pressure X Speed Factor
Full-Load Pressure = 1.4 X 1.00
plying 1780 cfm cooling air which is below minimum for
GE776 Motorized Wheels. This may be caused by a
problem in the air supply system. Check past airflow
test records to see if the original airflow test had a differĆ
ent value.

NOTES

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 MOTORIZED WHEEL AIRFLOW TESTING, GEK-91664

30.0
29.921

29.0

28.0

27.0

26.0

25.0
PRESSURE (INCHES OF MERCURY)

24.0

23.0

22.0

21.0

20.0

19.0

18.0

17.0

16.0

0 2000 4000 6000 8000 10000 12000 14000 16000

ALTITUDE (FEET ABOVE SEA LEVEL)

FIG. 9. STANDARD ATMOSPHERIC BAROMETRIC PRESSURE VS. ALTITUDE. E-41283.

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GEK-91664, MOTORIZED WHEEL AIRFLOW TESTING

DENSITY OF DRY AIR (LB./CU. FT.) VS. AMBIENT CONDITIONS

DRY BULB TEMPERATURE - DEGREES FARENHEIT

-30 -20 -10 0 10 20 30 40 50 60 70 80 90 100 110 120 130

16

17

0.040
18

19

20 0.045
BAROMETRIC PRESSURE - INCH MERCURY

21

22

AIR DENSITY (LB./CU.FT.)

0.050

23

24
0.055

25

26

0.060
27

28

29 0.065

30

31
0.070

32
0.085 0.080 0.075

FIG. 10. AIR DENSITY CHART (41A239793, SH 8, CHG 0). E-33559A.

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 MOTORIZED WHEEL AIRFLOW TESTING, GEK-91664

AIR DENSITY (LB./CU. FT.)

0.085

0.080

0.075

0.070

0.065

0.060

0.055

0.050
1680
MIN.
6

0.045

5 0.040
MOTORIZED WHEEL PRESSURE DIFFERENCIAL - INCH WATER

AIR DENSITY (LB./CU.FT.)

3

0
1400 1600 1800 2000 2200 2400 2600 2800
AIR FLOW (CFM)

FIG. 11. GE772 MOTORIZED WHEEL AIRFLOW - CFM (41A239793, SH 9, CHG 0). E-33560A.

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GEK-91664, MOTORIZED WHEEL AIRFLOW TESTING

0.085

0.080
7

0.075

0.070

6
0.065

0.060
PRESSURE DIFFERENTIAL (INCHES OF WATER)

5
0.055

AIR DENSITY (LB./CU.FT.)

0.050

4 0.045

0.040

1400 1600 1800 2000 2200 2400 2600 2800

AIR FLOW (CFM)

FIG. 12. GE776 AND GE791 MOTORIZED WHEEL AIRFLOW CURVES AT VARIOUS DENSITIES. E-41285.

12
 MOTORIZED WHEEL AIRFLOW TESTING, GEK-91664

7 0.085

0.080

0.075
6

0.070

0.065

5
0.060

0.055
PRESSURE DIFFERENTIAL (INCHES OF WATER)

0.050
4

AIR DENSITY (LB./CU.FT.)

0.045

0.040

1400 1600 1800 2000 2200 2400 2600 2800

AIR FLOW (CFM)

FIG. 13. GE787 AND GE788 MOTORIZED WHEEL AIRFLOW AT VARIOUS DENSITIES. E-41284.

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GEK-91664, MOTORIZED WHEEL AIRFLOW TESTING

GE Transportation
Systems
2901 East Lake Road
NEW 9-93, WLF Erie, Pennsylvania 16531
PRINTED
IN U.S.A.
E

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