GE

Transportation
Mining

CTRLPSB001 –
Installation Procedure for
17KG535 Control Group Dirt
Ingestion Abatement Kit

T. Acri
I. DESCRIPTION and OBJECT of CHANGE
The objective is to apply dirt ingestion abatement kit 84A221925G1 to affected 17KG535
control cabinets. Audits of cabinets both in the field and in production have revealed several
locations with high potential of allowing dirt/dust entry. Installation of this kit seals those
dirt entry locations.

II. DOCUMENTS REQUIRED/RECOMMENDED

Field modification 84A221925G1
Application of Manus Bond Caulking P7A-EP4

III. ONE 84A221925G1 MOD KIT REQUIRED PER CABINET Consisting of

Item Quantity GE Part number Description
1 1 tube 497A806P27 MANUS SEALANT
2 4 84A215344P1 PLUG
3 6 N22P25012B13 BOLT 3/8 x 0.75
4 6 N402P43B13 WASHER 3/8
5 4 N22P39024B13 BOLT 1.00 x 1.5 (OPTIONAL)
6 4 N402P20B13 WASHER NAR 1.00 (OPTIONAL)
7 2 lbs 41A319329P1 MORTITE SEALANT
8 6 N405P43B13 LOCKWASHER 3/8

IV. SPECIAL TOOLS / PROCESSES REQUIRED

- Caulking gun with flexible tip
- Socket Set (1/2”, 9/16”, ¾”, 1.5”)
.
V. POSSIBLE SYSTEMS AFFECTED
Any 240-360 Ton AC Electric Drive System Trucks equipped with 17KG535 IGBT
control cabinets.

VI. INSTALLATION PROCEDURE

WARNING:
Electric shock can cause serious or fatal injury. To avoid such injury,
personnel should take and observe proper precautions when making system
adjustments or performing system or component electrical tests. This
includes, but is not limited to, ensuring that all equipment is de-energized,
including energy storage components such as capacitors.
VI. INSTALLATION PROCEDURE CONT’D

1. Make sure that the engine is stopped and the DC link is discharged before working
in the main control box.
Follow all shop specific lockout and tag out procedures.
NOTE: left is the retarder side of the compartment, right is the operator’s cab side.
2. Remove the doors from the motor cable area at the rear of the compartment and
all doors on the front of the compartment. Also, remove the air inlet duct if it is
attached. The auxiliary compartment will need to be removed if installed.
3. Ensure that all surfaces where Mortite and Manus will be applied are clean, dry, and
completely free of dust and oil. Clean and dry as required.
4. Rear of Cabinet - Inspect all visible intermittent (skip) welds to ensure that Manus
sealant has been properly applied between each weld. Reapply where necessary.
Refer to Figures 1 – 7 below.

7 7

22 7

Figure 1. Rear View of 17KG535 Cabinet

 Figure 2. 17KG535 Rear View, Retarder Side,
Air Inlet Area

Figure 3. 17KG535 Rear View, Cab Side, Aux

Compartment Area
 Figure 4. 17KG535 Rear View, Cab Side, Aux
Compartment Area (INTERNAL)

OPTIONAL LIFTING
LUG HOLE PLUGS
5
6

3
4
8

Figure 5. 17KG535 Rear View, Roof

3 4
 3 4 8

Figure 6. 17KG535 Rear View, Rectifier Area

Figure 7. 17KG535 Rear View, LEM Compartment

VI. INSTALLATION PROCEDURE CONT’D

5. Contactor Compartment - Inspect all visible intermittent (skip) welds to ensure

that Manus sealant has been properly applied between each weld. Reapply
where necessary. Refer to Figures 8 - 10 below.

7
Figure 8. 17KG535 Retarder Side – Contactor Compartment
 Figure 9. 17KG535 Contactor Compartment - Rear Side

Figure 10. 17KG535 Contactor Compartment - Front Side

7
 6. Front of Cabinet - Inspect all visible intermittent (skip) welds to ensure that
Manus sealant has been properly applied between each weld. Reapply where
necessary. Refer to Figures 11 - 15 below.

Figure 11. 17KG535 Front View

7
1

7
Figure 12. 17KG535 Front Cab Side - AFSE Area

Figure 13. 17KG535 Front Retarder Side - Weldment View

 1

Figure 14. 17KG535 Front Retarder

Side

Figure 15. 17KG535 Center Post - TOP

1
 Figure 15. 17KG535 Center Post - BOTTOM

7. Reinstall all panels, doors and covers removed previously.

VII. CHECKOUT PROCEDURE

Start up the truck and allow the drive system to perform its normal “self test”.

CONTACT GE MINING PRODUCT SERVICE WITH QUESTIONS @ 814-875-6262